JP6765602B2 - Solenoid coil and its manufacturing method - Google Patents

Description

The present invention relates to a solenoid coil and a method for manufacturing the same, and more particularly to a solenoid coil used for wireless power feeding using a magnetic field resonance coupling (or a magnetic field resonance method) and a method for manufacturing the solenoid coil.

In recent years, attention has been paid to wireless power feeding using magnetic field resonance coupling, which enables power to be supplied to a position separated by several tens of centimeters to several meters.

By the way, when an alternating current is passed through a coil, a frequency called a resonance frequency is used when certain conditions are met, depending on the inductance, resistance value, and capacitance of the coil itself and the parameters of the elements that make up the circuit other than the coil. It is known to oscillate at. In wireless power feeding using magnetic field resonance coupling, it is known that the power feeding efficiency is good when the Q value with the inductance, resistance value, and capacitance of the coil as parameters is high.

The larger the inductance, the higher the Q value. When the number of turns of the coil is the same, the shorter the coil length, the higher the Q value can be obtained. Therefore, it is better that the gap between the conductors is small.

However, in the conventional solenoid coil, the wound adjacent wires are parallel wires, and when a high frequency current such as the HF band is passed, the wires generated between the wound adjacent wires and the wires are generated. In order to prevent the inter-capacity from increasing and the power supply efficiency from decreasing, a gap is provided between the conductors and the length of the coil is lengthened to maintain the magnitude of the Q value and obtain better power supply efficiency. It was difficult.

By the way, in Patent Document 1, a multi-layer wiring board in which a non-circular ring-shaped wiring pattern is formed in a plurality of layers and the ends of the wiring patterns between the layers are connected by conductor vias is taken as an example of each layer. Describes a loop antenna used for communication equipment such as RFID (Radio Frequency Identification) using the HF band, which is a single conductive path by connecting the wiring patterns in a row so as not to be parallel to each other. Has been done.

Japanese Unexamined Patent Publication No. 2009-267761

However, in order to wirelessly supply a relatively large amount of electric power to the loop antenna having the above-mentioned multi-layer wiring board structure used in communication equipment, such as an electric vehicle, it is necessary to increase the value of the current flowing through the coil. Yes, in a coil that is patterned on a substrate, the cross-sectional area of copper is limited compared to the conducting wire, so if the value of the flowing current is increased, heat will be generated, making it unsuitable for wireless power supply of large power. ..

In the present invention, in order to solve the above problems, in a solenoid coil in which a wire is wound, the wire is wound in an elliptical or polygonal ring surface shape, and the ring surface shape of the wound ring is changed for each winding. It is an object of the present invention to provide a solenoid coil having a stable power feeding efficiency for wireless power feeding of a relatively large amount of power and a method for manufacturing the same, by adopting a structure in which the coil is sequentially rotated and fixed in the wheel surface direction.

The present invention provides the following solenoid coil in order to solve the above problems.
(1) In a solenoid coil in which a conducting wire is wound in an elliptical or polygonal ring surface shape, the ring surface shape for each winding is sequentially rotated in the ring surface direction, and the adjacent conducting wires are fixed to each other. A solenoid coil characterized by having a structure fixed by means.
(2) A solenoid coil in which a lead wire is wound in an elliptical or polygonal ring surface shape, and a plurality of elliptical or polygonal plate pieces are sequentially rotated in the plate surface direction and laminated on the side surface of the bobbin. A solenoid coil characterized by having a structure in which a wire is wound and the ring surface shape of the winding wheel is sequentially rotated in the wheel surface direction for each winding.
(3) In the method of manufacturing a solenoid coil in which a lead wire is wound in an elliptical or polygonal ring surface shape, a through hole is provided in an elliptical or polygonal plate piece, and a plurality of through rods are passed through the through hole to stack a plurality of pieces. Then, the lead wire is wound around the side surface of the jig formed by sequentially rotating in the plate surface direction, and the ring surface shape of the winding ring has a structure in which the ring surface shape is sequentially rotated in both directions for each winding. A method of manufacturing a solenoid coil characterized by.

According to the present invention, it is possible to provide a good solenoid coil having stable power feeding efficiency and a method for manufacturing the same by maintaining a short length and a high Q value in transmission / reception of wireless power feeding of relatively large power.

The solenoid coil of the present invention is shown. The winding method of the solenoid coil of the present invention is shown. Another solenoid coil of the present invention is shown. An example of the bobbin of the present invention is shown. A jig for manufacturing a solenoid coil as the air core coil of the present invention is shown.

The conducting wire used in the present invention is an electrically conductive wire, and an enamel wire having an insulating material coated on the surface of the conductor, an electric wire in which the conducting wire is covered with an insulating member, or the like can be used. The cross section of the conducting wire is not particularly limited, such as circular or square. In addition to a single wire, a stranded wire consisting of multiple single wires can also be used. As the thickness of the conductor not including the insulating layer of the conducting wire, a conductor having a diameter of 0.025 mm to 3.2 mm can be used as specified in the JIS standard. The material of the conducting wire may be one that can be used for electric wires, and copper, aluminum, alloys thereof, superconducting wires such as niobium-titanium wire, and the like can be used.

The fixing means of the present invention fixes adjacent conducting wires to each other, and fixes them by the following method.
For example, a thermoplastic resin coated on the surface of a wire is wound, and while pressing from both sides of the wound solenoid coil, heating-cooling or energization heating is performed, and the coated thermoplastic resin is melted and solidified to partially melt and solidify. To fix the wires adjacent to each other
After winding the lead wire, apply an adhesive such as epoxy with a heat resistant temperature of 200 ° C or higher to the contact point between the lead wire and fix it.
After winding the lead wire, part or all of the solenoid coil is depp coated with insulating resin, etc.
After winding the lead wire, laminate it from both sides of the solenoid coil while pressing it with an adhesive sheet or a heat fusion sheet.
Further, as in the method shown below, there is a method of pressing the lead wire against the bobbin to wind and fix it.
By this fixing means, the gap between the conducting wires can be narrowed as much as possible and fixed, so that a solenoid coil with stable power feeding efficiency can be obtained.

The bobbin of the present invention is a core material for winding a lead wire, and is wound and fixed along the core material.
The shape of the bobbin is a bobbin formed by sequentially rotating a plurality of elliptical or polygonal plate pieces in the plate surface direction, and the material of the bobbin is compared with engineering plastics such as Teflon, Bakelite, and polyacetal, and engineering plastics. An insulating material such as acetylated wood having a small linear thermal expansion coefficient and a specific dielectric constant of about 1 to 3 is desirable.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 shows the solenoid coil of the present invention. FIG. 1 (a) shows a front view, and FIG. 1 (b) shows a side view. The innermost coil wheel portion 1 is the first winding, the coil ring portion 2 and the coil ring portion 3 are the second and third windings, respectively, and the foremost coil ring portion 9 is the ninth winding. This represents a solenoid coil with a total of 9 turns. At the position 4 where the adhesive is applied, adjacent conductors are applied and fixed in the region shown by hatching as shown in FIG.

FIG. 2 shows how to wind the solenoid coil. The coil is wound by tilting the coil wheel portion 2 wound the second time as shown by the arrow 10 after the first winding with respect to the center line 11 of the coil wheel portion 1 wound the first time. The central axis 21 of the coil of the coil ring portion 2 for the second time can be tilted at an arbitrary angle with respect to the central axis 11 of the coil of the ring portion 1. Since the first coil ring portion 1 and the second coil ring portion 2 come into contact with each other at the positions indicated by the circles 22, the adhesive may be applied to the positions 22 of the circles. By repeating this work, the central axes of the coils wound a plurality of times can be tilted, so that a structure that does not form a parallel conducting wire can be obtained.

FIG. 3 shows another solenoid coil of the present invention. The shape when it is wound once is a pentagon, and it is wound a total of nine times. Since the central axis 32 and the central axis 33 of the second and third coils are respectively inclined and wound at an angle of about 8 degrees with respect to the central axis 31 of the first coil, the adjacent conductors are parallel conductors. It is not.

FIG. 4 shows an example of the bobbin of the present invention.
FIG. 4A shows a front view of the bobbin when it is wound using the bobbin, and FIG. 4B shows a perspective view. A resin material having a plate thickness approximately the same as the thickness of the conductor, for example, bakelite having a plate thickness of 0.65 mm is formed into a pentagon and nine sheets are processed. Then, 9 sheets are bonded together with an adhesive or the like so that the central axis (not shown) of the bobbin 51 is tilted by about 8 degrees. By winding the lead wire around the side surface 52 of the bobbin 51, the solenoid coil as shown in FIG. 4 can be wound.

Alternatively, like a stereolithography or a 3D printer, it can be formed as an integral bobbin while laminating resin materials, or it can be formed by cutting.

Further, FIG. 5 shows a jig for manufacturing a solenoid coil as an air-core coil without using the bobbin of the present invention. 5 (a) is a front view, FIG. 5 (b) is a side view, FIG. 5 (c) is a front view of a winding plate around which a conducting wire is wound, and FIG. 5 (d) is a side view of the winding plate. ing.
The winding plate 71 is a pair of plates divided into upper and lower parts as shown in FIG. 5C, and a gap 93 is provided so that the winding plate 71 can be removed after the winding is completed. The hole 91 is a hole for determining the position of the winding plate 71 through the round bar 73, and is provided with a hole 92 for laminating at an angle. By sequentially stacking such winding plates 71, the structure as shown in FIGS. 5A and 5B is obtained, and a solenoid coil is formed by winding a lead wire around the side surface 93 of the winding plate 71. To. After fixing the coil with an adhesive or the like, if the pin or the like inserted into the round bar 73 or the hole 92 is removed, since there is a gap 93, the coil can be removed in sequence. The shape of the winding plate 71 and other constituent parts can be changed according to the shape of the coil.

1 ... Coil ring part, 2 ... Coil ring part, 3 ... Coil ring part 4 ... Position where adhesive is applied 9 ... Coil ring part 10 ... Arrow indicating the second winding direction,
11 ... Coil central axis, 21 ... Coil central axis,
22 ... Adhesive application positions 31, 32, 33 ... Coil center axis,
51 ... Bobbins of other embodiments

Claims (3)

In a solenoid coil in which a conducting wire is wound in an elliptical or polygonal ring surface shape, the ring surface shape for each winding is sequentially rotated in the ring surface direction, and the adjacent conducting wires are fixed to each other by fixing means. Solenoid coil characterized by having a structure that is. The wire is wound on the side surface of a bobbin in which a plurality of elliptical or polygonal plate pieces are sequentially rotated in the plate surface direction in a solenoid coil wound in an elliptical or polygonal ring surface shape. A solenoid coil characterized by having a structure in which the ring surface shape of the winding wheel is rotated sequentially in the wheel surface direction for each winding. In the method of manufacturing a solenoid coil in which a lead wire is wound in an elliptical or polygonal ring surface shape, a through hole is provided in an elliptical or polygonal plate piece, and a plurality of through rods are laminated through the through hole to form a plate. It is characterized by having a structure in which the lead wire is wound around a side surface of a jig formed by sequentially rotating in the surface direction, and the ring surface shape of the winding ring is sequentially rotated in both directions for each winding. How to manufacture a solenoid coil.