Coil structure and winding method

Abstract

A coil structure (100) and a winding method. The coil structure (100) comprises a coil bobbin (10), at least two coils and at least one insulation layer (40), wherein the coil bobbin (10) comprises a winding shaft (11) and a limiting portion (12), the winding shaft (11) being connected to the limiting portion (12), and the limiting portion (12) being provided with an inlet groove (121) and / or an outlet groove (122); and in the radial direction of the winding shaft (11), at least one coil is wound around the outer peripheral side of the winding shaft (11) and is defined as a first coil (20), and at least another coil is wound around the outer peripheral side of the insulation layer (40) and is defined as a second coil (30).

Description

Coil structure and winding method

[0001] Related applications

[0002] This application claims priority to the Chinese patent application filed on December 26, 2023, with application number 202311815292.X and invention name “Coil Structure and Winding Method”, the entire contents of which are incorporated by reference into this application. Technical Field

[0003] The present application relates to the technical field of electromagnetic coils, and in particular to a coil structure and a winding method. Background Art

[0004] In solenoid valve technology, to enhance the electromagnetic force of the coil structure, the coil structure can be wound using two or more layers of coils. When the valve is open, the two or more layers of coils are connected in parallel for power supply, which reduces the starting voltage, shortens the valve opening time, and achieves better valve opening performance. However, during operation, the adjacent parts of the multi-layer coils are the head and tail of the coils, and leads are required at the head and tail of the coils. This can easily damage the insulation of the coil, affecting safety. Summary of the Invention

[0005] According to various embodiments of the present application, a coil structure and a winding method are provided.

[0006] A coil structure comprises a coil skeleton, at least one insulating layer and at least two coils; the coil skeleton comprises a winding shaft and a limiting portion, the limiting portions are connected to both ends of the winding shaft along its own axial direction, and the limiting portions protrude from the winding shaft along the radial direction of the winding shaft; any one of the limiting portions is provided with an entry slot and / or an exit slot; along the radial direction of the winding shaft, at least one insulating layer is provided between any two adjacent coils, and at least one coil is wound around the outer circumference of the winding shaft and defined as a first coil, and at least another coil is wound around the outer circumference of the insulating layer and defined as a second coil; wherein the head lead of the first coil and the head lead of the second coil are respectively located in the entry slot, and the tail lead of the first coil and the tail lead of the second coil are respectively located in the exit slot.

[0007] In one embodiment, the coil structure further includes a fixed layer, which is wound around the outer circumference of the insulating layer and is located between the outer circumference of the insulating layer and the inner circumference of the second coil.

[0008] In one embodiment, the fixing layer is configured as a heat shrinkable tape, and the heat shrinkable tape is fixed to the outer side of the insulating layer by heating and shaping.

[0009] In one embodiment, the winding tension of the heat shrinkable tape is between 300N and 500N; and / or the heating and setting temperature of the heat shrinkable tape is between 150°C and 170°C; and / or the heating and setting time of the heat shrinkable tape is between 10h and 12h.

[0010] In one embodiment, in the inlet slot and / or the outlet slot, there is a gap between any two adjacent coils, and the gap is filled with insulating filler.

[0011] In one embodiment, the portion of the limiting portion facing the winding shaft and protruding from the winding shaft is provided with the entry groove and the exit groove, and the entry groove and the exit groove are connected; the winding shaft is provided with a lead slope, and the lead slope is connected to the groove wall of the entry groove and / or the groove wall of the exit groove.

[0012] In one embodiment, the width of the inlet slot is greater than the width of the outlet slot.

[0013] In one embodiment, the inlet slot includes a straight section and a gradually expanding section connected to the straight section, and the slot depth of the gradually expanding section gradually increases along its length direction from the straight section toward the outlet slot.

[0014] In one embodiment, part of the head lead of the first coil and part of the head lead of the second coil extend out of the inlet slot respectively; and / or part of the tail lead of the first coil and part of the tail lead of the second coil extend out of the outlet slot respectively.

[0015] In one embodiment, high temperature resistant glue is applied between the ends of the head leads of any two adjacent coils; and / or high temperature resistant glue is applied between the ends of the tail leads of any two adjacent coils.

[0016] The present application also provides a winding method, which is applied to the above-mentioned coil structure; the winding method includes the following steps: winding a first coil on the outer peripheral side of a winding shaft; winding an insulating layer on the outer peripheral side of the first coil; and winding a second coil on the outer peripheral side of the insulating layer.

[0017] In one embodiment, before the step of winding the second coil around the outer periphery of the insulating layer, a fixing layer is wound around the outer periphery of the insulating layer.

[0018] In one embodiment, winding the fixing layer on the outer circumference of the insulating layer includes: tightly winding the fixing layer along the circumference of the first coil; and heating the fixing layer at a first temperature and continuously heating for a first time.

[0019] In one embodiment, winding the first coil on the outer periphery of the winding shaft includes: installing the head lead of the first coil in the entrance slot, and extending part of the head lead of the first coil from the entrance slot; installing the tail lead of the first coil in the exit slot, and extending part of the tail lead of the first coil from the exit slot.

[0020] In one embodiment, winding the second coil on the outer peripheral side of the insulating layer includes: installing the head lead of the second coil in an entrance slot, and extending a portion of the head lead of the second coil from the entrance slot; installing the tail lead of the second coil in an exit slot, and extending a portion of the tail lead of the second coil from the exit slot.

[0021] The details of one or more embodiments of the present application are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the present application will become apparent from the description, drawings, and claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to better describe and illustrate the embodiments and / or examples of the inventions disclosed herein, reference may be made to one or more of the accompanying drawings. The additional details or examples used to describe the accompanying drawings should not be considered to limit the scope of the disclosed inventions, the presently described embodiments and / or examples, and any of the best modes currently understood for these inventions.

[0023] FIG1 is a schematic diagram of a coil structure provided in this application.

[0024] FIG2 is a schematic structural diagram of a coil skeleton in the coil structure provided in this application.

[0025] Figure numerals: 100, coil structure; 10, coil skeleton; 11, winding axis; 111, lead slope; 12, limiting portion; 121, entrance slot; 1211, straight section; 1212, gradually expanding section; 122, exit slot; 20, first coil; 30, second coil; 40, insulation layer; 50, fixed layer. DETAILED DESCRIPTION

[0026] To make the above-mentioned objects, features, and advantages of the present application more clearly understood, the specific embodiments of the present application are described in detail below with reference to the accompanying drawings. The following description sets forth many specific details to facilitate a full understanding of the present application. However, the present application can be implemented in many other ways than those described herein, and those skilled in the art can make similar improvements without violating the scope of the present application. Therefore, the present application is not limited to the specific embodiments disclosed below.

[0027] It should be noted that when a component is referred to as being "fixed to" or "disposed on" another component, it may be directly on the other component or there may be a central component. When a component is considered to be "connected to" another component, it may be directly connected to the other component or there may be a central component at the same time. The terms "vertical", "horizontal", "upper", "lower", "left", "right" and similar expressions used in the specification of this application are for illustrative purposes only and do not represent the only implementation method.

[0028] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being referred to. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of such features. Throughout the description of this application, "plurality" means at least two, for example, two, three, etc., unless otherwise specifically defined.

[0029] In this application, unless otherwise expressly specified or limited, when a first feature is "above" or "below" a second feature, it can mean that the first feature is directly in contact with the second feature, or the first feature and the second feature are indirectly in contact through an intermediary. Furthermore, when a first feature is "above," "above," or "above" a second feature, it can mean that the first feature is directly above or diagonally above the second feature, or simply means that the first feature is higher in level than the second feature. When a first feature is "below," "below," or "below" a second feature, it can mean that the first feature is directly below or diagonally below the second feature, or simply means that the first feature is lower in level than the second feature.

[0030] Unless otherwise defined, all technical and scientific terms used in the specification of this application have the same meaning as commonly understood by those skilled in the art to which this application belongs. The terms used in the specification of this application are only for the purpose of describing specific embodiments and are not intended to limit this application. The term "and / or" used in the specification of this application includes any and all combinations of one or more of the relevant listed items.

[0031] Referring to Figures 1 and 2, the present application provides a coil structure 100, which includes a coil skeleton 10, at least two coils and at least one insulating layer 40; the coil skeleton 10 includes a winding shaft 11 and a limiting portion 12, and the winding shaft 11 is connected to the limiting portion 12 at both ends along its own axial direction, and the limiting portion 12 protrudes from the winding shaft 11 in the radial direction of the winding shaft 11; any limiting portion 12 is provided with an entry slot 121 and / or an exit slot 122; along the radial direction of the winding shaft 11, at least one insulating layer 40 is provided between any two adjacent coils, and at least one coil is wound around the outer circumference of the winding shaft 11 and is defined as a first coil 20, and at least another coil is wound around the outer circumference of the insulating layer 40 and is defined as a second coil 30; wherein the head lead of the first coil 20 and the head lead of the second coil 30 are respectively located in the entry slot 121, and the tail lead of the first coil 20 and the tail lead of the second coil 30 are respectively located in the exit slot 122.

[0032] In this way, the coil skeleton 10 facilitates the assembly of the first coil 20 and the second coil 30. Specifically, the first coil 20 and the second coil 30 are wound on the winding shaft 11, and the limiting portion 12 has a limiting effect on the first coil 20 and the second coil 30 along the axial direction of the winding shaft 11, so that the first coil 20 and the second coil 30 are stably assembled. An insulating layer 40 is provided between the first coil 20 and the second coil 30 to enhance the insulation performance of the coil and prevent the insulating shell of any one of the first coil 20 and the second coil 30 from being damaged and connected to cause a short circuit. In more embodiments, multiple second coils 30 can be provided, and an insulating layer 40 is provided between any two adjacent second coils 30 to enhance the insulation.

[0033] During the assembly of the first coil 20 and the second coil 30, the setting of the entrance groove 121 on the coil frame 10 can accommodate the head lead of the first coil 20 and the head lead of the second coil 30, which has the function of limiting protection, reducing the probability of shaking and wear of the head lead of the first coil 20 and the head lead of the second coil 30, making the insulating shell of the head lead of the first coil 20 and the head lead of the second coil 30 not easily damaged, thereby improving the insulation performance.

[0034] When the coil structure 100 is applied to a solenoid valve, with at least two coils connected in parallel, both coils can be powered simultaneously when the valve is open. This significantly increases the magnetomotive force, thereby increasing the electromagnetic force generated by the coils and accelerating the solenoid valve's response time. When the solenoid valve is fully open, the branch containing at least one coil is powered, while the branches containing the other coils are de-energized. This power cycle is repeated periodically. During long-term operation of the solenoid valve, the temperature rise of the first coil 20 and the second coil 30 is reduced, minimizing the risk of coil burnout. This reduces overall operating power consumption and improves the solenoid valve's operational stability.

[0035] For ease of explanation, the present application is described with one first coil 20 and one second coil 30 . When there are multiple second coils 30 , reference can be made to the contents of the embodiments of the present application.

[0036] It should be noted that during the assembly process, in the entrance slot 121, along the radial direction of the winding shaft 11, the head lead of the first coil 20 is close to the winding shaft 11 relative to the head lead of the second coil 30. Correspondingly, in the exit slot 122, the tail lead of the first coil 20 is close to the winding shaft 11 relative to the tail lead of the second coil 30, so as to provide space for the assembly of the second coil 30.

[0037] In further embodiments, a gap is provided between the first coil 20 and the second coil 30 in the inlet slot 121 and / or the outlet slot 122. This gap is filled with an insulating filler to enhance insulation between the first coil 20 and the second coil 30 and to increase thermal resistance therebetween, thereby improving heat resistance and extending service life. When multiple second coils 30 are provided, in addition to the insulating filler between the first coil 20 and the second coil 30 in the inlet slot 121 and / or the outlet slot 122, the gap between any two adjacent second coils 30 is also filled with insulating filler to enhance insulation performance.

[0038] As shown in Figure 2, in a specific embodiment, the portion of the limiting portion 12 facing the winding shaft 11 and protruding from the winding shaft 11 is provided with an entry groove 121 and an exit groove 122, and the entry groove 121 and the exit groove 122 are connected; the winding shaft 11 is provided with a lead slope 111, and the lead slope 111 is connected to the groove wall of the entry groove 121 and / or the groove wall of the exit groove 122.

[0039] Thus, the lead slope 111 serves as a guide, facilitating winding of the first coil 20 or the second coil 30 along the slope of the lead slope 111, thereby improving assembly efficiency. The interconnection between the entry slot 121 and the exit slot 122 facilitates simultaneous connection of the lead slope 111 with the walls of both the entry slot 121 and the exit slot 122, placing the entry slot 121 and the exit slot 122 close to the winding shaft 11, thereby facilitating assembly of the first coil 20 and the second coil 30.

[0040] As shown in Figure 2, in some embodiments, the width of the entry slot 121 is greater than the width of the exit slot 122. Because the sizes of the first coils 20 vary, the starting point of the winding of the second coil 30 also varies. The wider entry slot 121 provides ample space for the lead wires of the second coil 30, adapting to different first coil 20 sizes. Furthermore, since the position of the lead wires of the second coil 30 is relatively fixed after winding, the exit slot 122 does not need to reserve a large space for the second coil 30, thus reducing material loss.

[0041] As shown in FIG2 , in a further embodiment, the entry slot 121 includes a straight section 1211 and a gradually expanding section 1212 connected to the straight section 1211. The depth of the gradually expanding section 1212 gradually increases along its length from the straight section 1211 toward the exit slot 122. As such, since the lead wires of the first coil 20 and the lead wires of the second coil 30 tend to escape toward the winding shaft 11 when assembled into the entry slot 121, the depth of the entry slot 121 gradually increases to provide the lead wires with sufficient space to float toward the winding shaft 11, thereby increasing the retaining effect and preventing the lead wires from escaping.

[0042] In this specific embodiment, portions of the head leads of the first coil 20 and the head leads of the second coil 30 extend out of the inlet slot 121, respectively; portions of the tail leads of the first coil 20 and the tail leads of the second coil 30 extend out of the outlet slot 122. This ensures that both the first coil 20 and the second coil 30 have sufficient length for connection to an external power source, facilitating current conduction.

[0043] During the actual assembly process, the head lead of the first coil 20 and the head lead of the second coil 30 located outside the inlet slot 121 are both reserved with a certain length of insulating shell, and the reserved lengths of the two are the same; the tail lead of the first coil 20 or the tail lead of the second coil 30 located outside the outlet slot 122 is reserved with a certain length of insulating shell, and the reserved lengths of the two are the same. This arrangement can avoid short circuits caused by the connection between the first coil 20 and the second coil 30, enhance insulation, and improve safety of use. When there are multiple second coils 30, the reserved lengths of the multiple second coils 30 outside the inlet slot 121 or outside the outlet slot 122 are the same as the reserved length of the first coil 20.

[0044] In a further embodiment, a high-temperature resistant adhesive is applied between the ends of the head leads of the first coil 20 and the head leads of the second coil 30; and / or a high-temperature resistant adhesive is applied between the ends of the tail leads of the first coil 20 and the tail leads of the second coil 30. This ensures a more reliable and stable bonding between the head leads and / or tail leads of the first coil 20 and the second coil 30, facilitates centralized storage of the head leads and / or tail leads, and facilitates connection to an external power source. When there are multiple second coils 30, a high-temperature resistant adhesive is applied between the ends of the head leads of any two adjacent second coils 30, and a high-temperature resistant adhesive is applied between the ends of the tail leads of any two adjacent second coils 30.

[0045] As shown in Figure 1 , in addition to adding the insulating layer 40, the present application also adds a fixing layer 50. The fixing layer 50 is wound around the outer periphery of the insulating layer 40 and is located between the outer periphery of the insulating layer 40 and the inner periphery of the second coil 30. In this way, the fixing layer 50 tightly wraps the first coil 20, thereby facilitating the winding stability of the second coil 30.

[0046] As shown in Figure 1 , in this specific embodiment, the fixing layer 50 is wrapped around the outer periphery of the insulating layer 40 and positioned between the outer peripheral sidewall of the insulating layer 40 and the inner peripheral sidewall of the second coil 30. In this manner, by heating the heat shrink tape, the tape gradually tightens around the first coil 20, ensuring stable assembly of the first coil 20 and simplifying operation.

[0047] In actual operation, it is necessary to ensure that the tension of the heat shrink tape is between 300N and 500N to completely and tightly wrap the first coil 20. For example, the tension of the heat shrink tape is 300N, 400N or 500N.

[0048] In some embodiments, the heat shrinkable tape is heated and set at a temperature between 150°C and 170°C to ensure that the heat shrinkable tape undergoes sufficient shrinkage and deformation to meet the required winding tension. Exemplarily, the heat shrinkable tape is heated and set at a temperature of 150°C, 160°C, or 170°C.

[0049] In some embodiments, the heat shrink tape is heated and set for 10 to 12 hours to set the deformation of the heat shrink tape and ensure that the heat shrink tape maintains sufficient winding tension on the first coil 20 for a long time. Exemplarily, the heat shrink tape is heated and set for 10, 11, or 12 hours.

[0050] The present application also provides a winding method, which is applied to the above-mentioned coil structure 100; the winding method includes the following steps: winding the first coil 20 on the outer peripheral side of the winding shaft 11; winding the insulating layer 40 on the outer peripheral side of the first coil 20; and winding the second coil 30 on the outer peripheral side of the insulating layer 40. In this way, the use of the first coil 20 and the second coil 30 can enhance the electromagnetic effect and promote performance improvement. The provision of the insulating layer 40 is conducive to enhancing the insulation of the first coil 20 and the second coil 30, so as to ensure safety of use while improving performance. When there are multiple second coils 30, continue to repeat the action of winding an insulating layer 40 on the outer peripheral side of the second coil 30, and then wind the new second coil 30 on the insulating layer 40.

[0051] In an optional embodiment, before the step of winding the second coil 30 around the outer periphery of the insulating layer 40 , a fixing layer 50 is wound around the outer periphery of the insulating layer 40 to fix the first coil 20 and facilitate the winding stability of the second coil 30 .

[0052] In a specific embodiment, wrapping the fixing layer 50 around the outer circumference of the insulating layer 40 includes: tightly wrapping the fixing layer 50 along the circumference of the first coil 20; and heating the fixing layer 50 at a first temperature for a first time. The first temperature is the heating setting temperature of the fixing layer 50, and the first time is the heating setting time of the fixing layer 50. For details, refer to the above embodiment and are not further described here.

[0053] In a specific embodiment, winding the first coil 20 around the outer circumference of the winding shaft 11 includes: installing the head lead of the first coil 20 in the entry slot 121, and extending a portion of the head lead of the first coil 20 from the entry slot 121; and installing the tail lead of the first coil 20 in the exit slot 122, and extending a portion of the tail lead of the first coil 20 from the exit slot 122. In this manner, the head lead and tail lead of the first coil 20 can be connected to corresponding power sources to achieve current conduction.

[0054] In another specific embodiment, winding the second coil 30 around the outer periphery of the insulating layer 40 includes: installing the head lead of the second coil 30 in the entry slot 121, and partially extending the head lead of the second coil 30 from the entry slot 121; and installing the tail lead of the second coil 30 in the exit slot 122, and partially extending the tail lead of the second coil 30 from the exit slot 122. In this manner, the head lead and the tail lead of the second coil 30 can be connected to corresponding power sources to achieve current conduction.

[0055] The technical features of the above-mentioned embodiments can be combined arbitrarily. In order to make the description concise, not all possible combinations of the technical features in the above-mentioned embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0056] The above-described embodiments merely represent several implementation methods of the present application. While the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that a person of ordinary skill in the art may make various modifications and improvements without departing from the spirit of the present application, and these modifications and improvements fall within the scope of protection of the present application. Therefore, the scope of protection of the present patent application shall be determined by the appended claims.

Claims

1. A coil structure, characterized in that, Comprising: A coil bobbin, including a winding shaft and a limiting portion. Both ends of the winding shaft along its own axial direction are connected with the limiting portion, and the limiting portion protrudes radially from the winding shaft along the radial direction of the winding shaft; Any one of the limiting portions is provided with an inlet groove and / or an outlet groove; At least two coils and at least one insulating layer. Along the radial direction of the winding shaft, at least one insulating layer is provided between any two adjacent coils, and at least one coil is wound around the outer peripheral side of the winding shaft and defined as the first coil, and at least another coil is wound around the outer peripheral side of the insulating layer and defined as the second coil; Wherein, the head leads of the first coil and the head leads of the second coil are respectively located in the inlet groove, and the tail leads of the first coil and the tail leads of the second coil are respectively located in the outlet groove.

2. The coil structure according to claim 1, wherein, The coil structure further includes a fixing layer, and the fixing layer is wound around the outer peripheral side of the insulating layer and is located between the outer peripheral side of the insulating layer and the inner peripheral side of the second coil.

3. The coil structure according to claim 2, wherein, The fixing layer is set as a heat-shrinkable tape, and the heat-shrinkable tape is fixed on the outer side of the insulating layer through heat setting.

4. The coil structure according to claim 3, wherein, The winding tension of the heat-shrinkable tape is between 300N and 500N; and / or, the heat setting temperature of the heat-shrinkable tape is between 150°C and 170°C; and / or, the heat setting time of the heat-shrinkable tape is between 10h and 12h.

5. The coil structure according to claim 1, wherein, In the inlet groove and / or the outlet groove, there is a gap between any two adjacent coils, and the gap is filled with an insulating filler.

6. The coil structure according to claim 1, wherein, The part of the limiting portion facing the winding shaft and protruding from the winding shaft is provided with the inlet groove and the outlet groove, and the inlet groove and the outlet groove are communicated; The winding shaft is provided with a lead slope surface, and the lead slope surface is connected with the groove wall of the inlet groove and / or the groove wall of the outlet groove.

7. The coil structure according to claim 1, wherein, The width of the inlet groove is greater than the width of the outlet groove.

8. The coil structure according to claim 1, wherein, The inlet groove includes a straight section and a gradually expanding section connected to the straight section, and the groove depth dimension of the gradually expanding section gradually increases along its own length direction from the straight section towards the outlet groove.

9. The coil structure according to claim 1, wherein, Part of the head leads of the first coil and part of the head leads of the second coil respectively extend out of the inlet groove; and / or, part of the tail leads of the first coil and part of the tail leads of the second coil respectively extend out of the outlet groove.

10. The coil structure according to claim 1, wherein, High-temperature resistant glue is applied between the heads of the head leads of any two adjacent coils; and / or, high-temperature resistant glue is applied between the heads of the tail leads of any two adjacent coils.

11. A winding method, characterized in that, Applied to the coil structure according to any one of claims 1 to 10; The winding method includes the following steps: Winding the first coil around the outer peripheral side of the winding shaft; Winding the insulating layer around the outer peripheral side of the first coil; Winding the second coil around the outer peripheral side of the insulating layer.

12. The winding method according to claim 11, wherein, Before the step of winding the second coil around the outer peripheral side of the insulating layer, winding the fixing layer around the outer peripheral side of the insulating layer.

13. The winding method according to claim 12, wherein, Winding the fixing layer around the outer peripheral side of the insulating layer includes: Winding the fixing layer tightly along the circumferential direction of the first coil; Heating the fixing layer at a first temperature and continuously heating for a first time.

14. The winding method according to claim 11, wherein, The step of winding the first coil around the outer peripheral side of the winding shaft includes: Install the head lead of the first coil in the entrance groove and extend part of the head lead of the first coil out of the entrance groove; Install the tail lead of the first coil in the exit groove and extend part of the tail lead of the first coil out of the exit groove.

15. The winding method according to claim 11, wherein, Winding the second coil around the outer peripheral side of the insulating layer includes: Install the head lead of the second coil in the entrance groove and extend part of the head lead of the second coil out of the entrance groove; Install the tail lead of the second coil in the exit groove and extend part of the tail lead of the second coil out of the exit groove.

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