Transformer and method for manufacturing a transformer

Abstract

To provide a transformer and a manufacturing method of the transformer, capable of easily arranging a plurality of coils in parallel.SOLUTION: A transformer according to the present disclosure, comprises: an annular frame body 2; a plurality of coils that is formed in an outer periphery of the frame body 2 so that a conductive wire 3a is wound in a peripheral direction, and which is paralleled in an axial length direction of the frame body 2; and insulation walls 4 that stand on the outer periphery and separates the adjacent coils over the whole periphery. In the transformer, the plurality of coils is formed of one continuous conductive wire 3a. The conductive wire 3a extending from a winding end part of one coil formed on the outer periphery on one surface side of the insulation wall 4 crosses over the insulation wall 4, and is continued to a winding start part of the other coil formed in the outer periphery on the other surface side of the insulation wall 4.SELECTED DRAWING: Figure 4

Description

Technical Field

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[0001] The present disclosure relates to a transformer and a method for manufacturing a transformer.

Background Art

[0002] <​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​The transformer according to the present disclosure comprises an annular frame, a plurality of coils formed on the outer circumference of the frame by winding a conductor in the circumferential direction and arranged in the axial direction of the frame, and an insulating wall erected on the outer circumference and separating adjacent coils over its entire circumference, wherein the plurality of coils consist of a single continuous conductor, and the conductor extending from the end of winding of one coil formed on the outer circumference on one side of the insulating wall crosses over the insulating wall and continues to the beginning of winding of another coil formed on the outer circumference on the other side of the insulating wall. The transformer according to this disclosure comprises an annular frame, a plurality of coils formed on the outer circumference of the frame by winding a conductor in the circumferential direction and arranged in the axial direction of the frame, and an insulating wall erected on the outer circumference and separating adjacent coils over its entire circumference, wherein the plurality of coils consist of a single continuous conductor, the conductor extending from the end of winding of one coil formed on the outer circumference on one side of the insulating wall crosses over the insulating wall and continues to the beginning of winding of another coil formed on the outer circumference on the other side of the insulating wall, the insulating wall is provided with a guide portion for guiding the conductor that crosses over the insulating wall, and the guide portion is an inclined groove with a guide slope as its bottom surface that extends downstream in the winding direction of the conductor from the tip of the one side of the insulating wall toward the base of the other side of the insulating wall. The transformer according to this disclosure comprises an annular frame, a plurality of coils formed on the outer circumference of the frame by winding a conductor in the circumferential direction and arranged in the axial direction of the frame, and an insulating wall erected on the outer circumference and separating adjacent coils over the entire circumference, wherein the plurality of coils consist of a single continuous conductor, the conductor extending from the end of winding of one coil formed on the outer circumference on one side of the insulating wall crosses over the insulating wall and continues to the beginning of winding of another coil formed on the outer circumference on the other side of the insulating wall, the insulating wall is provided with a guide portion for guiding the conductor that crosses over the insulating wall, the guide portion is an inclined groove with a guide slope as its bottom surface that extends downstream in the winding direction of the conductor from the tip of the one side of the insulating wall toward the base of the other side of the insulating wall, and the other side of the insulating wall is The guide portion has a first inclined portion adjacent to the other coil in the axial direction and inclined with respect to the circumferential direction, a second inclined portion spaced a suitable length from the guide portion in the circumferential direction and inclined with respect to the circumferential direction, and a parallel portion located between the first and second inclined portions and parallel with respect to the circumferential direction, wherein the downstream end of the first inclined portion in the winding direction of the conductor is located on the side of the one surface by the length of the outer diameter of the conductor compared to the upstream end, and the upstream end of the second inclined portion in the winding direction of the conductor is located on the side of the one surface by the length of the outer diameter of the conductor compared to the downstream end, the guide portion guides the conductor so that the starting portion of the winding of the other coil is in contact with the other surface, the frame has a wall portion adjacent to the other surface of the insulating wall, the inner dimensions in the axial direction between the insulating wall and the insulating wall are constant in the circumferential direction, and the other coil is arranged between the insulating wall and the wall portion.

[0007] In this disclosure, multiple coils consist of a single continuous wire. Therefore, the work of connecting the wires to each other is unnecessary. Consequently, workers are not forced to perform complicated connection procedures to ensure that the wires are securely connected, and multiple coils can be easily installed side by side.

[0008] The transformer according to this disclosure is characterized in that the insulating wall is provided with a guide portion for guiding the conductor that crosses the insulating wall.

[0009] In this disclosure, the guide portion provided on the insulating wall guides the conductor over the insulating wall, so that the conductor can smoothly overcome the insulating wall.

[0010] The transformer according to this disclosure is characterized in that the guide portion has a guide slope that extends downstream in the winding direction of the conductor from the tip of one surface of the insulating wall toward the base end of the other surface of the insulating wall.

[0011] In this disclosure, the guide section has a guide slope. When crossing an insulating wall, the conductor is guided by a guide slope from the leading edge of one side of the insulating wall to the base edge of the other side. Since the guide slope extends in the direction in which the conductor is wound, it is particularly useful, for example, when winding the conductor by rotating the frame, allowing the conductor to cross the insulating wall while continuing to rotate the frame.

[0012] The transformer according to the present disclosure is characterized in that the other surface of the insulating wall has a first inclined portion adjacent to the guide portion in the axial direction and inclined with respect to the circumferential direction, a second inclined portion spaced a suitable length from the guide portion in the circumferential direction and inclined with respect to the circumferential direction, and a parallel portion located between the first inclined portion and the second inclined portion and parallel with respect to the circumferential direction, the downstream end of the first inclined portion in the winding direction of the conductor is located on the side of the one surface by the length of the outer diameter of the conductor compared to the upstream end, the upstream end of the second inclined portion in the winding direction of the conductor is located on the side of the one surface by the length of the outer diameter of the conductor compared to the downstream end, the guide portion guides the conductor so that the starting portion of the other coil is in contact with the other surface, the frame has a wall portion adjacent to the other surface of the insulating wall and having an inner dimension in the axial direction between it and the insulating wall that is constant in the circumferential direction, and the other coil is arranged between the insulating wall and the wall portion.

[0013] In this disclosure, the other surface of the insulating wall has a first inclined portion and a second inclined portion that are inclined with respect to the circumferential direction. The displacement between the upstream and downstream ends of each inclined portion is the width of one conductor. The other coils are arranged in the space between the insulating wall and the wall section. With respect to this space, the inner dimensions in the axial direction of the frame are constant in the circumferential direction of the frame. Therefore, the other coils can be wound in an aligned manner so that the conductors are along the other side of the insulating wall or the side of the wall section facing the insulating wall.

[0014] When crossing an insulating wall, an external force is applied to the conductor in the direction from one side of the insulating wall to the other side. Therefore, the starting point of another coil is prone to curvature that separates it from the other side of the insulating wall. However, the starting point of another coil comes into contact with the other side of the insulating wall because the conductor is guided by the guide. Furthermore, the conductor extending from the starting point of the winding comes into contact with the second inclined section during the first winding of the frame, and is guided in a direction that is one conductor width away from where the starting point of the coil on the other side of the insulating wall is in contact. Therefore, it is possible to prevent the starting point of the second winding after crossing the insulating wall from interfering with the starting point of the first winding.

[0015] The transformer according to this disclosure is characterized in that the conductors constituting each of the plurality of coils are wound in multiple layers in an aligned manner around the outer circumference, and a spacer is provided between the end of the first winding of the first layer of the other coil and the first inclined portion.

[0016] In this disclosure, each coil is formed by winding multiple layers of wire in an aligned manner. When forming the first layer of other coils during the manufacture of the transformer, the conductor that has gone around the frame is guided in a direction that moves away from the other side of the insulating wall by the start of the next turn. Since the first inclined portion is inclined toward one side of the insulating wall with respect to the circumferential direction, the end of the first turn of the first layer moves away from the first inclined portion on the other side of the insulating wall. However, since there is a spacer between the end of the first turn of the first layer and the first inclined portion on the other side of the insulating wall, there is no risk of a gap forming between them.

[0017] The conducting wire forming the first layer is directly wound around the frame body, and the conducting wire forming the second layer is directly wound around the first layer. Since there is a spacer between the end portion of the first turn of the first layer and the first inclined portion on the other surface of the insulating wall, there is no possibility of a gap occurring between the two. Therefore, it is possible to prevent the conducting wire forming the second layer from falling into the gap generated in the first layer. Accordingly, it is possible to prevent the conducting wire forming the third layer from falling into the gap generated when the conducting wire forming the second layer falls into the first layer. The same applies to the conducting wires forming the fourth layer and above. As a result, it is possible to prevent the disturbance of the aligned winding due to the falling of the conducting wire to the lower layer.

[0018] The transformer according to the present disclosure is characterized in that the length of the spacer from the first inclined portion is not more than the radius of the conducting wire.

[0019] In the present disclosure, since the dimensions of the spacer are appropriately set, there is no possibility that the spacer disturbs the aligned winding of the coil. If the dimension of the spacer from the first inclined portion on the other surface of the insulating wall is longer than the radius of the conducting wire, there is a possibility that the spacer interferes with the conducting wire of the first layer and disturbs the aligned winding.

[0020] [Appendix] The transformer according to the present disclosure is characterized in that the length of the spacer from the first inclined portion is longer toward the downstream side in the winding direction of the conducting wire.

[0021] In the present disclosure, when viewed in the winding direction of the conducting wire, the spacer becomes larger in the axial direction of the frame body. Since the end portion of the first turn of the first layer of the other coil gradually separates from the first inclined portion on the other surface of the insulating wall, the gap between the two can be appropriately filled with the spacer.

[0022] A method for manufacturing a transformer according to the present disclosure comprises an annular frame, a plurality of coils formed on the outer circumference of the frame by winding a conductor in the circumferential direction and arranged in the axial direction of the frame, and an insulating wall erected on the outer circumference and separating adjacent coils over its entire circumference, characterized in that one coil is formed by winding the conductor around the outer circumference of one side of the insulating wall while rotating the frame about its axis, after the formation of the first coil, the conductor is moved in the axial direction toward the other side of the insulating wall while rotating the frame so that the conductor extending from the end of the first coil crosses over the insulating wall, and another coil is formed by winding the conductor that has crossed the insulating wall around the outer circumference of the other side of the insulating wall while rotating the frame. A method for manufacturing a transformer according to the present disclosure comprises an annular frame, a plurality of coils formed on the outer circumference of the frame by winding a conductor in the circumferential direction and arranged in the axial direction of the frame, and an insulating wall erected on the outer circumference and separating adjacent coils over the entire circumference, wherein the method involves rotating the frame about its axis and winding the conductor around the outer circumference on one side of the insulating wall to form one coil, and after the formation of the one coil, rotating the frame and moving the conductor toward the other side of the insulating wall in the axial direction. This is characterized by the fact that the conductor extending from the end of the first coil's winding passes over the insulating wall, and when the conductor passes over the insulating wall, it is guided by a guide portion provided on the insulating wall, the guide portion being an inclined groove with a guide slope as its bottom surface that extends downstream in the winding direction of the conductor from the tip of one side of the insulating wall toward the base of the other side of the insulating wall, and by rotating the frame and winding the conductor that has passed over the insulating wall around the outer circumference of the other side of the insulating wall, another coil is formed. A method for manufacturing a transformer according to the present disclosure comprises an annular frame, a plurality of coils formed on the outer circumference of the frame by winding a conductor in the circumferential direction and arranged in the axial direction of the frame, and an insulating wall erected on the outer circumference and separating adjacent coils over its entire circumference, wherein the method involves rotating the frame about its axis and winding the conductor around the outer circumference of one side of the insulating wall to form one coil, and after the formation of the one coil, rotating the frame and moving the conductor in the axial direction toward the other side of the insulating wall so that the conductor extending from the end of the winding of the one coil crosses over the insulating wall, and when the conductor crosses over the insulating wall, it is guided by a guide portion provided in the insulating wall, the guide portion being an inclined groove with a guide slope as its bottom surface that extends downstream in the winding direction of the conductor from the tip of the one side of the insulating wall toward the base of the other side of the insulating wall, and the frame is located on the other side of the insulating wall The insulating wall has adjacent wall portions with an inner dimension in the axial direction between them and the insulating wall being constant in the circumferential direction, and by rotating the frame, the conductor that has crossed the insulating wall is wound around the outer circumference of the other side of the insulating wall to form another coil between it and the wall portion, and when the conductor is guided to the guide portion, it is guided so that the starting portion of the other coil is in contact with the other side, and the other side of the insulating wall has a first inclined portion adjacent to the guide portion in the axial direction and inclined with respect to the circumferential direction, a second inclined portion spaced a suitable length from the guide portion in the circumferential direction and inclined with respect to the circumferential direction, and a parallel portion between the first inclined portion and the second inclined portion and parallel with respect to the circumferential direction, and the downstream end of the first inclined portion in the winding direction of the conductor is located on the side of the one side by the length of the outer diameter of the conductor compared to the upstream end, and the upstream end of the second inclined portion in the winding direction of the conductor is located on the side of the one side by the length of the outer diameter of the conductor compared to the downstream end.

[0023] In the present disclosure, after forming one coil on one side of the insulating wall, the conducting wire crosses over the insulating wall and moves from one side of the insulating wall to the other side, and another coil is formed on the other side of the insulating wall. As a result, a transformer composed of a plurality of coils made of a single continuous conducting wire can be manufactured. Moreover, since the frame is not stopped when the frame is rotated to form a coil by winding the conducting wire around the frame and the conducting wire is made to cross over the insulating wall, automation of the parallel arrangement of the coils can be achieved.

[0024] [Appendix] The method for manufacturing a transformer according to the present disclosure is characterized in that, after forming the one coil, while rotating the frame provided with the insulating wall, the guide portion for guiding the conducting wire crossing over the insulating wall, the conducting wire is moved in the axial length direction toward the other side of the insulating wall, so that the conducting wire extending from the end portion where winding of the one coil ends is guided by the guide portion and crosses over the insulating wall.

[0025] In the present disclosure, the guide portion provided on the insulating wall allows the conducting wire to smoothly cross over the insulating wall while rotating the frame.

[0026] [Appendix] The method for manufacturing a transformer according to the present disclosure is such that the other surface of the insulating wall has a first inclined portion adjacent to the guide portion in the axial direction and inclined with respect to the circumferential direction, a second inclined portion spaced a suitable length from the guide portion in the circumferential direction and inclined with respect to the circumferential direction, and a parallel portion located between the first inclined portion and the second inclined portion and parallel with respect to the circumferential direction, wherein the downstream end of the first inclined portion in the winding direction of the conductor is located on the side of the one surface by the length of the outer diameter of the conductor than the upstream end, and the conductor of the second inclined portion The upstream end in the winding direction is located on the side of the one surface by the length of the outer diameter of the conductor compared to the downstream end, the insulating wall is provided with a guide portion that guides the conductor so that the starting portion of the coil is in contact with the other surface, and the frame is rotated, having a wall portion adjacent to the other surface side of the insulating wall, with an inner dimension in the axial direction between it and the insulating wall being constant in the circumferential direction, and the conductor is wound along the other surface when forming the other coil, thereby forming the other coil between the insulating wall and the wall portion.

[0027] In this disclosure, when forming other coils, the conductor is wound along the other surface of the insulating wall, thereby forming other coils between the insulating wall and the wall portion. Since the inner dimensions in the axial direction of the frame between the insulating wall and the wall portion are constant, the coils can be wound in an aligned manner so that the conductor is wound along the other surface of the insulating wall or the surface of the wall portion facing the insulating wall.

[0028] The starting point of the other coil is guided by the guide section, bringing it into contact with the other surface of the insulating wall. The other surface of the insulating wall has a first inclined section and a second inclined section that are inclined with respect to the circumferential direction. The displacement between the upstream and downstream ends of each inclined section is the width of one wire. The wire extending from the starting point of the other coil is guided in a direction that is one wire width away from one surface of the insulating wall than the starting point by contacting the second inclined section. Therefore, interference between the starting point of the second winding and the starting point of the first winding after crossing the insulating wall can be prevented. [Effects of the Invention]

[0029] According to the transformer and method for manufacturing the transformer of this disclosure, multiple coils can be easily arranged side by side. [Brief explanation of the drawing]

[0030] [Figure 1] This is an exploded perspective view of the transformer according to Embodiment 1. [Figure 2] This is a perspective view of the top edge of the frame. [Figure 3] This is a perspective view of the insulating wall of the frame. [Figure 4] This is a plan view of the frame. [Figure 5] This is a bottom view of the frame. [Figure 6] This is a plan view illustrating the coil formation procedure. [Figure 7] This is a plan view illustrating the coil formation procedure. [Figure 8] This is an enlarged perspective view of the frame of the transformer according to Embodiment 2. [Figure 9] This is a schematic plan view illustrating the function of a spacer. [Figure 10] This is a schematic cross-sectional view illustrating the width and height of the spacer. [Modes for carrying out the invention]

[0031] Embodiments of this disclosure will be described below. In the following description, the terms top and bottom, front and back, and left and right, indicated by arrows in the figures, will be used.

[0032] Embodiment 1. Figure 1 is an exploded perspective view of the transformer according to Embodiment 1. In the figure, 1 is a transformer, and the transformer 1 comprises a coil bobbin 11, two secondary coils 12 and 13, a cover 14, and two wound cores (not shown). The coil bobbin 11 comprises a frame 2 and coils 31 to 34. Coils 31 to 34 are primary coils.

[0033] Frame 2 has a rectangular ring shape. The four corners of frame 2 are curved in an arc shape. Frame 2 is an insulator, and is made of, for example, synthetic resin. The left and right sides of frame 2 are its two long sides, and the top and bottom sides of frame 2 are its two short sides. The direction parallel to the long sides of frame 2 corresponds to the up and down direction, and the direction parallel to the short sides of frame 2 corresponds to the left and right direction. The axial length direction of frame 2 corresponds to the front and back direction. In the following, the circumferential direction of frame 2 will simply be referred to as the circumferential direction.

[0034] A groove 21 is provided on the outer circumference of the frame 2. The groove 21 extends around the entire circumference of the frame 2. Window portions 22 are provided in the front wall 21a of the groove 21 at both the upper and lower edges of the frame 2. The window portions 22 are rectangular in shape, formed by cutting out the front wall 21a from the top to the bottom. Similarly, window portions 22 are also provided in the rear wall 21b of the groove 21 at both the upper and lower edges of the frame 2 (see Figures 2, 4, and 5 described later). Three insulating walls 4 are arranged side by side in the front-to-rear direction between the front wall 21a and the rear wall 21b of the groove 21. Each insulating wall 4 extends around the entire circumference of the frame 2, rising radially outward from the bottom surface of the groove 21.

[0035] Coils 31-34 are located inside the groove 21 and are arranged in this order from front to back. Each of the coils 31-34 is formed by winding a conductor 3a (see Figures 4, 6, and 7 described later) around the bottom surface of the groove 21 in the circumferential direction. The conductors 3a constituting each of the coils 31-34 are wound in an aligned manner. The direction in which the conductor 3a is wrapped around the frame 2 is such that it passes through the top, left, bottom, and right surfaces of the frame 2 in that order. Hereafter, the upstream / downstream side of the wrapping direction around the frame 2 will simply be referred to as the upstream / downstream side. At the top edge of the frame 2, the upstream / downstream side is the right / left side, and at the bottom edge of the frame 2, the upstream / downstream side is the left / right side.

[0036] Coil 31 is positioned between the front side wall 21a and the foremost insulating wall 4. The foremost insulating wall 4 is interposed between coil 31 and coil 32. The central insulating wall 4 is interposed between coil 32 and coil 33. The last insulating wall 4 is interposed between coil 33 and coil 34. Coil 34 is positioned between the last insulating wall 4 and the rear side wall 21b of the groove 21. Coils 31-34 consist of a single continuous wire 3a. That is, coils 31-34 are connected in series with each other. Since each of coils 31-34 is small in the front-to-back direction, even if the alignment of the windings of the wire 3a constituting any of the coils is partially disrupted, there is no risk of a large change in the voltage across coils 31-34.

[0037] The end of the winding of coil 31 is in contact with the front surface of the foremost insulating wall 4. The conductor 3a extending from coil 31 crosses over the foremost insulating wall 4 and continues to the beginning of the winding of coil 32. The beginning of the winding of coil 32 is in contact with the rear surface of the foremost insulating wall 4. Similarly, the end of the winding of coil 32 is in contact with the front surface of the central insulating wall 4. The conductor 3a extending from coil 32 crosses over the central insulating wall 4 and continues to the beginning of the winding of coil 33. The beginning of the winding of coil 33 is in contact with the rear surface of the central insulating wall 4. Furthermore, the end of the winding of coil 33 is in contact with the front surface of the last insulating wall 4. The conductor 3a extending from coil 33 crosses over the last insulating wall 4 and continues to the beginning of the winding of coil 34. The beginning of the winding of coil 34 is in contact with the rear surface of the last insulating wall 4.

[0038] The wires 3a constituting coil 31 are generally parallel to the circumferential direction of frame 2. On the other hand, the wires 3a constituting coils 32 to 34 are inclined forward relative to the circumferential direction of frame 2 at the upper edge of frame 2, and inclined backward relative to the circumferential direction of frame 2 at the lower edge of frame 2.

[0039] The secondary coil 12 has a rectangular ring shape and is housed radially inside the coil bobbin 11. The secondary coil 13 also has a rectangular ring shape. The coil bobbin 11 is housed radially inside the secondary coil 13. The secondary coils 12 and 13 are formed, for example, by bending a flat wire.

[0040] The cover 14 comprises two cover members 141. Each cover member 141 integrally has two semi-cylinders adjacent to each other on the left and right, and the axial length of each semi-cylinder extends vertically. By combining the two cover members 141, a cover 14 having two cylinders is formed. The left cylinder of cover 14 passes inside the secondary coil 12 and covers the left sides of the coil bobbin 11 and the secondary coils 12 and 13, respectively. Similarly, the right cylinder of cover 14 covers the right sides of the coil bobbin 11 and the secondary coils 12 and 13, respectively. A cylindrical wound iron core (not shown) is provided on the outer surface of each of the two cylinders of the cover 14.

[0041] Figure 2 is a perspective view of the upper edge of frame 2. Figure 3 is a perspective view of the insulating wall 4 of the frame 2. Only one insulating wall 4 is shown in Figure 3. Figure 4 is a plan view of frame 2. In Figure 4, the conductor wire 3a is shown as a dashed line. Each insulating wall 4 is provided with an inclined groove 5. The inclined groove 5 extends roughly in the left-right direction from the center of the circumferential direction of the insulating wall 4 at the upper edge of the frame 2. The depth direction of the inclined groove 5 is downward. One side of the inclined groove 5 in the longitudinal direction opens at the front end of the insulating wall 4. The other side of the inclined groove 5 in the longitudinal direction opens at the base end of the rear surface of the insulating wall 4.

[0042] The inclined groove 5 is a guide section that guides the conductor 3a over the insulating wall 4. The inclined groove 5 has a guide slope 51 and two inner surfaces 52 and 53. The guide slope 51 is the bottom surface of the inclined groove 5 and is an inclined surface that descends from the right end to the left end. The inner surfaces 52 and 53 rise from both ends of the guide slope 51 in the width direction, respectively. The inner surfaces 52 and 53 are adjacent to each other in the front-to-back direction. Each of the inner surfaces 52 and 53 is an inclined surface that is located further forward from the right end to the left end.

[0043] A guide surface 521 extends to the left from the left end of the front inner surface 52. The guide surface 521 has the function of guiding the conductor 3a from between the inner surfaces 52 and 53 of the inclined groove 5 to the rear surface of the insulating wall 4 in a leftward direction. The guide surface 521 at the foremost insulating wall 4 guides the conductor 3a so that the starting portion of the coil 32 is in contact with the rear surface of the foremost insulating wall 4 next to the inclined groove 5. Similarly, the guide surface 521 at the middle (last) insulating wall 4 guides the conductor 3a so that the starting portion of the coil 33 (coil 34) is in contact with the rear surface of the middle (last) insulating wall 4 next to the inclined groove 5.

[0044] A guide surface 531 extends to the right from the right end of the rear inner surface 53. The guide surface 531 has the function of guiding the conductor 3a from the front of the insulating wall 4 to the space between the inner surfaces 52 and 53 of the inclined groove 5, moving to the left. The guide surface 531 on the foremost insulating wall 4 guides the conductor 3a extending from the end of the coil 31 winding into the inside of the inclined groove 5. Similarly, the guide surface 531 on the middle (last) insulating wall 4 guides the conductor 3a extending from the end of the coil 32 (coil 33) winding into the inside of the inclined groove 5.

[0045] The rear surface of each insulating wall 4 has two inclined portions 41 and 42 and a parallel portion 43 (see Figures 3, 4, and Figure 5 described later). As shown in Figures 3 and 4, the inclined portion 41 (first inclined portion) is located on the upper edge of the frame 2. The inclined portion 41 is adjacent to the rear side of the inclined groove 5 and is inclined with respect to the circumferential direction. The left end of the inclined portion 41 is located further forward than the right end of the inclined portion 41 by the length of the outer diameter of the conductor 3a. In other words, the inclined portion 41 is an inclined surface that is located further forward towards the downstream side. The left end of the inclined portion 41 is located at the left opening of the inclined groove 5.

[0046] Figure 5 is a bottom view of frame 2. As shown in Figures 3 and 5, the inclined portion 42 (second inclined portion) is located on the lower edge of the frame 2. The inclined portion 42 is inclined with respect to the circumferential direction. The right end of the inclined portion 42 is located further back than the left end of the inclined portion 42 by the length of the outer diameter of the conductor 3a. In other words, the inclined portion 42 is an inclined surface that is located further back the downstream side. The inclined portion 42 may be located on the left or right side of the frame 2.

[0047] As shown in Figures 3 to 5, the parallel section 43 is located between the downstream side of the inclined section 41 and the upstream side of the inclined section 42, and between the downstream side of the inclined section 42 and the upstream side of the inclined section 41. The parallel section 43 is parallel to the circumferential direction.

[0048] As shown in Figures 2, 4, and 5, the rear surface of the front wall 21a and the front surface of the foremost insulating wall 4 are both parallel to the circumferential direction. Therefore, the inner dimension in the front-to-back direction between the front wall 21a and the foremost insulating wall 4 is constant in the circumferential direction.

[0049] As shown in Figures 4 and 5, the front surfaces of the central and last insulating walls 4 each have two inclined portions 411 and 421 that face and are parallel to the inclined portions 41 and 42, and a parallel portion 431 that faces and is parallel to the parallel portion 43. Therefore, the inner dimension in the front-to-back direction between one insulating wall 4 and another insulating wall 4 (wall portion) adjacent to the rear side of one insulating wall 4 is constant in the circumferential direction. The front surface of the rear wall 21b also has two inclined sections that face and are parallel to the inclined sections 41 and 42, and a parallel section that faces and is parallel to the parallel section 43. Therefore, the inner dimensions in the front-to-back direction between the last insulating wall 4 and the rear wall 21b (wall section) are constant in the circumferential direction. However, a window section 22 is located in the middle of the inclined section of the rear wall 21b.

[0050] Figure 6 is a plan view illustrating the coil formation procedure. Figure 6 schematically shows only the central (or final) insulating wall 4 and the bottom surface of the groove 21. For clarity, the insulating wall 4 is hatched upwards to the right. The operator sets the frame 2 into the coil forming device 6, which is equipped with a reel 61 and a traverse 62. The frame 2, set in the coil forming device 6, is driven by a motor (not shown) provided in the coil forming device 6 and rotates around its axis in the direction indicated by the white arrow in Figure 3.

[0051] Here, the top, left, bottom, and right surfaces of the frame 2 shown in Figures 1 to 5 are referred to as surface A, surface B, surface C, and surface D. The frame 2 set in the coil forming apparatus 6 shown in Figure 6 rotates so that surface A, surface B, surface C, surface D, surface A... face upwards in this order. Figures 6A to 6D show the state where surfaces A to D are facing upwards, and Figure 6E shows the state where the frame 2 has completed one rotation and surface A is facing upwards again. The coil forming apparatus 6 is schematically shown only in Figure 6A.

[0052] The reel 61 supplies the conductor 3a to be wound around the frame 2. The worker pulls the conductor 3a from the reel 61 and guides it into the space between the front wall 21a and the foremost insulating wall 4 of the frame 2, which has not yet rotated. Next, the worker brings the conductor 3a into contact with the rear surface of the front wall 21a and pulls it out of the groove 21 through the window 22 in the front wall 21a. Furthermore, the worker temporarily fixes the starting end of the conductor 3a pulled out of the groove 21 to a jig (not shown) provided by the coil forming device 6.

[0053] After the wire 3a is fixed in place, the frame 2 rotates, causing the wire 3a to be continuously pulled out from the reel 61 and wound around the circumferential direction in the order of A side, B side, C side, D side, A side, ... On the A side, the upstream / downstream side is the D side / B side, and on the C side, the upstream / downstream side is the B side / D side.

[0054] The traverse 62 is a roller whose axial length is oriented in the front-to-back direction and is provided to be able to reciprocate in the front-to-back direction. The circumferential surface of the traverse 62 is provided with an engagement groove that extends around its entire circumference, and the conductor 3a, which is located between the reel 61 and the frame 2, engages with the engagement groove of the traverse 62. When the traverse 62 reciprocates in the front-to-back direction with the engagement groove of the traverse 62 facing the outer circumference of the frame 2, the position in which the conductor 3a wraps around the frame 2 is adjusted in the front-to-back direction. The operation of the traverse 62 is controlled by a control unit (not shown) provided in the coil forming device 6.

[0055] Coils 31 to 34 are formed in this order. For the sake of simplicity, each of coils 31 to 34 is formed by M layers of aligned winding, with N windings of conductor wire 3a per layer (M and N are natural numbers). In Figures 6A to 6E, the first winding of the first layer of coil 33 is shown on the right side of the insulating wall 4, and the same applies to the first winding of the first layer of coils 32 and 34. For clarity of the diagram, the beginning of the first winding of the first layer of coil 33 is hatched downwards to the right (see Figures 6A and 6E).

[0056] Here, we will explain the procedure for forming the coil 31. When forming an odd-numbered layer of coil 31, the conductor 3a is wound once in the order of A-side to D-side while in contact with the rear surface of the front side wall 21a. When the wound conductor 3a reaches surface A again, the traverse 62 moves backward by the outer diameter of the conductor 3a. As a result, the conductor 3a of the second turn of the odd-numbered layer is adjacent to the right side of the conductor 3a of the first turn of the odd-numbered layer. On surface A, the traverse 62 moves to the rear by the length of one wire 3a, and the wire 3a is wound around it a predetermined number of N times, thereby forming an odd number of layers of the coil 31.

[0057] When forming an even-numbered layer of coil 31, the conductor 3a is wound once in the order of A-side to D-side while in contact with the front surface of the foremost insulating wall 4. When the wound conductor 3a reaches surface A again, the traverse 62 moves forward by the outer diameter of the conductor 3a. As a result, the conductor 3a of the second winding of the even-numbered layer is adjacent to the right side of the conductor 3a of the first winding of the even-numbered layer. On surface A, the traverse 62 moves forward by the width of one wire 3a, and the wire 3a is wound around it a predetermined number of N times, thereby forming an even number of layers of the coil 31.

[0058] The coil 31 is completed when the M layer is formed. As the coil 31 is finished winding, the traverse 62 moves backward by a predetermined length. As the traverse 62 moves backward, a backward external force is applied to the conductor 3a. This external force causes the conductor 3a to move from the front to the rear of the foremost insulating wall 4 and to cross over the foremost insulating wall 4. When crossing over the insulating wall 4, the conductor 3a is guided into the inclined groove 5.

[0059] Specifically, the conductor 3a extending from the end of the coil 31 is guided by the guide surface 531 and led between the inner surfaces 52 and 53 of the inclined groove 5, and then guided by the guide slope 51, moving from the tip side to the base side of the foremost insulating wall 4. Subsequently, the conductor 3a is guided by the guide surface 521 and led from between the inner surfaces 52 and 53 of the inclined groove 5 to the rear surface of the foremost insulating wall 4 (see Figure 4). The inner surfaces 52 and 53 of the inclined groove 5 prevent the conductor 3a from falling out of the inclined groove 5 in the axial direction of the frame 2. As described above, the conductor 3a that has overcome the foremost insulating wall 4 forms the coil 32.

[0060] When forming odd-numbered layers of coil 32, the conductor 3a is wound once in the order of sides A to D while in contact with the rear surface of the foremost insulating wall 4 (see Figures 6A to 6D). The inclined portion 42 on the rear surface of the insulating wall 4 is inclined backward. In order to guide the conductor 3a along this, when the conductor 3a being wrapped around reaches surface C, the traverse 62 moves backward by the outer diameter of the conductor 3a. As a result, the wire 3a passing through surface D is located behind the wire 3a passing through surface B by the outer diameter of the wire 3a. Also, when the wound wire 3a reaches surface A again, the second winding of the odd-numbered layer's wire 3a is adjacent to the right of the first winding of the odd-numbered layer's wire 3a (see Figure 6E).

[0061] On the C-plane, the traverse 62 moves to the rear by the width of one wire 3a, and the wire 3a is wound around it a predetermined N times, thereby forming an odd number of layers of the coil 32.

[0062] Figure 7 is a plan view illustrating the coil formation procedure. Only the central (or final) insulating wall 4 and the bottom surface of the groove 21 are schematically shown in Figure 7. Figures 7A to 7D show the state with surfaces A to D facing upwards, and Figure 7E shows the state where the frame 2 has completed one rotation and surface A is facing upwards again. In Figures 7A to 7E, the first turn of the second layer of coil 33 is shown to the right of the insulating wall 4, and the same applies to the first turn of the second layer of coils 32 and 34, respectively. For clarity of the diagram, the beginning of the first turn of the second layer of coil 33 is hatched downwards to the right (see Figures 7A and 7E).

[0063] When forming an even-numbered layer of coil 32, the conductor 3a is wound once on each side in order from side A to side D while in contact with the front surface of the central insulating wall 4 (see Figures 7A to 7D). The inclined portion 411 on the front of the central insulating wall 4 is inclined forward (see Figure 4). In order to guide the conductor 3a along this, the traverse 62 moves forward by twice the outer diameter of the conductor 3a at the start of the first winding. The inclined portion 421 on the front of the central insulating wall 4 is inclined towards the rear (see Figure 5). In order to guide the conductor 3a along this, when the conductor 3a being wrapped around reaches the C-plane, the traverse 62 moves towards the rear by the outer diameter of the conductor 3a.

[0064] As a result of the above, the second winding of the even-numbered layer, wire 3a, is adjacent to the right of the first winding of the even-numbered layer, wire 3a. On side A, the traverse 62 moves forward by the width of two wires 3a, and on side C, the traverse 62 moves backward by the width of one wire 3a, while the wire 3a is wound around it a predetermined number of times, thereby forming an even number of layers of coil 32.

[0065] The coil 32 is completed when the M layer is formed. At the end of winding coil 32, the traverse 62 moves backward by a predetermined length, similar to the end of winding coil 31. As a result, the conductor 3a extending from the end of winding coil 32 is guided into the inclined groove 5 and crosses over the central insulating wall 4. Subsequently, coil 33 is formed by the conductor 3a that has crossed the central insulating wall 4, in the same manner as with coil 32.

[0066] At the end of winding coil 33, the traverse 62 moves backward by a predetermined length, similar to the end of winding coil 31. As a result, the conductor 3a extending from the end of winding coil 33 is guided into the inclined groove 5 and crosses the last insulating wall 4. After that, coil 34 is formed by the conductor 3a that has crossed the central insulating wall 4, in the same manner as in the case of coil 32. After the coil 34 has finished winding, the frame 2 stops rotating. The operator removes the frame 2 from the coil forming device 6.

[0067] According to the manufacturing method of the transformer 1 described above, the work of connecting the conductors 3a to each other is unnecessary. Therefore, since workers are not forced to perform complicated connection procedures to reliably connect the conductors 3a to each other, multiple coils 31 to 34 can be easily arranged side by side. Moreover, since the inclined groove 5 extends in the direction in which the conductors 3a are wound around the frame 2, there is no need to stop the rotation of the frame 2 while the coils 31 to 34 are being formed. Furthermore, the inclined groove 5 provided in the insulating wall 4 guides the conductor 3a as it crosses the insulating wall 4, allowing the conductor 3a to smoothly cross the insulating wall 4.

[0068] When crossing the insulating wall 4, a backward external force is applied to the conductor 3a by the traverse 62. Therefore, the starting points of each coil 32-34 tend to partially curve away from the rear surface of the insulating wall 4. However, since the inner surfaces 52 and 53 of the inclined groove 5 are inclined so that they are positioned further forward from the upper right end to the lower left end, the starting points of each coil 32-34 are guided by the inclined groove 5, causing the conductor 3a to contact the other surface of the insulating wall 4.

[0069] Furthermore, the conductor 3a, which extends from the starting point of the winding and makes one turn around the frame 2, comes into contact with the inclined portion 42 of the insulating wall 4 along the way, and is guided in a direction that is one wire length away from the point where the starting point of the winding on the other side of the insulating wall 4 is in contact. Therefore, it is possible to prevent the starting point of the second winding after crossing the insulating wall 4 from interfering with the starting point of the first winding.

[0070] Embodiment 2. Figure 8 is an enlarged perspective view of the frame 2 of the transformer 1 according to Embodiment 2. Each insulating wall 4 of the frame 2 is provided with a spacer 44 adjacent to the rear side of the inclined groove 5. Figure 9 shows the spacer 44 placed on the last insulating wall 4, but the spacers 44 placed on the other insulating walls 4 have a similar configuration.

[0071] The spacer 44 is integrally formed with the frame 2. The spacer 44 protrudes backward from the inclined portion 41 of the insulating wall 4 and rises radially outward from the bottom surface of the groove 21 of the frame 2. The spacer 44 extends in the winding direction of the conductor 3a from the upstream end of the inclined portion 41 to a suitable length downstream from the downstream end of the inclined portion 41. However, the downstream end of the spacer 44 does not interfere with the conductor 3a extending downstream from the inclined groove 5.

[0072] The rear surface of the spacer 44 is perpendicular to the axial direction of the frame 2 and parallel to the circumferential direction. Hereafter, the length from the inclined portion 41 of the spacer 44 to the rear surface of the spacer 44 will be referred to as the width of the spacer 44. The width of the spacer 44 is larger towards the downstream side, and the maximum width is equal to the radius of the conductor 3a. The upper surface of the spacer 44 is perpendicular to the radial direction of the frame 2 and parallel to the circumferential direction. Hereinafter, the length from the bottom surface of the groove 21 of the spacer 44 to the upper surface of the spacer 44 is referred to as the height of the spacer 44. The height of the spacer 44 is a predetermined value less than the diameter of the conductor 3a.

[0073] Figure 9 is a schematic plan view illustrating the function of the spacer 44. Figure 9 shows two adjacent insulating walls 4. The following explanation will use the case where the two insulating walls 4 are the first insulating wall 4 and the central insulating wall 4 as an example. Figure 10A shows the first layer of the coil 32, and Figure 10B shows the second layer of the coil 32. The conductors 3a constituting the first layer are wound directly around the bottom surface of the groove 21, and the conductors 3a constituting the second layer are wound directly around the first layer.

[0074] Guided by the inclined groove 5, the conductor 3a, having passed the first insulating wall 4, is wound once while in contact with the rear surface of the insulating wall 4, and then wound once more adjacent to the first wound conductor 3a from the rear. The end of the first winding extends parallel to the circumferential direction and is adjacent to the rear side of the inclined section 41.

[0075] On the other hand, the inclined section 41 is inclined so that it is located further forward towards the downstream side. Therefore, the end of the first winding gradually moves away from the inclined section 41 towards the downstream side. However, a spacer 44 exists between the end of the first winding and the inclined section 41. Moreover, the width of the spacer 44 gradually increases towards the downstream side. Therefore, there is no risk of a gap forming between the end of the first winding and the inclined section 41.

[0076] Therefore, the conductor 3a constituting the second layer is prevented from falling into the gap created in the first layer. Consequently, the conductor 3a constituting the third layer is prevented from falling into the gap created when the conductor 3a constituting the second layer falls into the first layer. The same applies to the conductor 3a constituting the fourth layer and above. As a result, it is possible to prevent disruption of the aligned winding due to the detachment of the conductor 3a to the lower layer.

[0077] Figure 10 is a schematic cross-sectional view illustrating the width and height of the spacer 44. In the diagram, the solid lines on the wires 3a that are hatched upwards to the right represent the end portions of the first and second turns of wire 3a that make up the first layer of coil 32. The front-to-back position of the end portion of the first (and second) turns of wire 3a that make up the first layer is the same as the front-to-back position of the beginning portion of the second (and third) turns of wire 3a that make up the first layer.

[0078] In the diagram, the solid lines on the conductor wires 3a that are hatched downwards to the right represent the end of the windings of the N-turn and {N-1}-turn conductor wires 3a that make up the second layer of the coil 32. The dashed line in the diagram shows the starting point of the first winding of the first turn of the wire 3a that makes up the first layer of the coil 32.

[0079] In this embodiment, the center position of the end of the first winding of the first layer of the conductor 3a is located behind the center position of the beginning of the winding by the length of the diameter of the conductor 3a. Therefore, the width of the spacer 44 is less than or equal to the radius of the conductor 3a. If the maximum width of the spacer 44 is greater than the radius of the conductor 3a, the spacer 44 may interfere with the conductor 3a that makes up the first layer, potentially disrupting the aligned winding of the first layer. The height of the spacer 44 must be such that it does not interfere with the conductor 3a that constitutes the second layer. Furthermore, it is desirable that the height of the spacer 44 be such that it can contact and support the N-wound conductor 3a that constitutes the second layer.

[0080] The embodiments disclosed herein should be considered in all respects to be illustrative and not restrictive. The scope of the present invention is intended to include, but not in the sense described above, the equivalents of the claims and all modifications within the claims. [Explanation of Symbols]

[0081] 1 Transformer; 2 Frame; 21b Rear wall (wall section); 31-34 Coil; 3a Conductor; 4 Insulating wall (wall section); 41,42 Inclined section (first inclined section); 43 Parallel section; 44 Spacer; 5 Inclined groove (guide section); 51 Guide slope

Claims

1. A ring-shaped frame, A plurality of coils are formed on the outer circumference of the frame by winding the conductor in the circumferential direction, and are arranged in the axial direction of the frame. An insulating wall erected on the outer circumference, separating adjacent coils around the entire circumference, In a transformer for playing, The aforementioned plurality of coils consist of a single continuous wire. The conductor extending from the end of one coil formed on the outer circumference of one side of the insulating wall crosses over the insulating wall and continues to the beginning of another coil formed on the outer circumference of the other side of the insulating wall. The insulating wall is provided with a guide portion for guiding the conductor over the insulating wall. The guide portion is an inclined groove with a guide slope as its bottom surface, which extends downstream in the winding direction of the conductor from the tip of one surface of the insulating wall toward the base of the other surface of the insulating wall. The other side of the insulating wall is The guide portion has a first inclined portion adjacent to it in the axial direction and inclined with respect to the circumferential direction, A second inclined portion is spaced appropriately apart from the guide portion in the circumferential direction and is inclined with respect to the circumferential direction, A parallel portion located between the first inclined portion and the second inclined portion, and parallel to the circumferential direction. It has, The downstream end of the first inclined portion in the winding direction of the conductor is located on the side of the surface by a length equal to the outer diameter of the conductor than the upstream end. The upstream end of the second inclined portion in the winding direction of the conductor is located on the side of the surface by a length equal to the outer diameter of the conductor than the downstream end. The guide portion guides the conductor so that the starting portion of the other coil is in contact with the other surface. The frame has a wall portion adjacent to the other side of the insulating wall, the inner dimension in the axial direction between it and the insulating wall is constant in the circumferential direction, A transformer characterized in that the other coil is arranged between the insulating wall and the wall portion.

2. The conductors constituting each of the aforementioned plurality of coils are wound in multiple layers in an aligned manner around the outer circumference. The transformer according to claim 1, characterized in that a spacer is provided between the end of the first winding of the first layer of the other coil and the first inclined portion.

3. The transformer according to claim 2, characterized in that the length of the spacer from the first inclined portion is less than or equal to the radius of the conductor.

4. A method for manufacturing a transformer comprising an annular frame, a plurality of coils formed on the outer circumference of the frame by winding a conductor in the circumferential direction and arranged in the axial direction of the frame, and an insulating wall erected on the outer circumference and separating adjacent coils over the entire circumference, By rotating the frame around its axis and winding the conductor around the outer circumference of one side of the insulating wall, a coil is formed. After the formation of the coil, the frame is rotated while the conductor is moved in the axial direction toward the other side of the insulating wall, so that the conductor extending from the end of the coil's winding passes over the insulating wall. When the conductor crosses the insulating wall, it is guided by a guide provided on the insulating wall. The guide portion is an inclined groove with a guide slope as its bottom surface, which extends downstream in the winding direction of the conductor from the tip of one surface of the insulating wall toward the base of the other surface of the insulating wall. The frame has a wall portion adjacent to the other side of the insulating wall, the inner dimension in the axial direction between it and the insulating wall is constant in the circumferential direction, While rotating the frame, the conductor that has crossed the insulating wall is wrapped around the outer circumference of the other side of the insulating wall, thereby forming another coil between it and the wall. When the conductor is guided to the guide portion, the starting portion of the other coil is guided so as to come into contact with the other surface. The other side of the insulating wall is The guide portion has a first inclined portion adjacent to it in the axial direction and inclined with respect to the circumferential direction, A second inclined portion is spaced appropriately apart from the guide portion in the circumferential direction and is inclined with respect to the circumferential direction, A parallel portion located between the first inclined portion and the second inclined portion, and parallel to the circumferential direction. It has, The downstream end of the first inclined portion in the winding direction of the conductor is located on the side of the surface by a length equal to the outer diameter of the conductor than the upstream end. A method for manufacturing a transformer, characterized in that the upstream end of the second inclined portion in the winding direction of the conductor is located on the side of the surface by a length equal to the outer diameter of the conductor than the downstream end.

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