JP2634001B2 - Thin coil - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a thin coil, and is applicable to, for example, a surface facing motor.

[0002]

BACKGROUND OF THE INVENTION Flat-panel coils used in conventional general plane facing the motor, as shown in FIG. 7, a plurality of winding coils 16 stator substrate comprising a magnet wire wound a predetermined number of times
17 in the circumferential direction. And the stator substrate 1
Generally, a frequency generator (hereinafter, referred to as “FG”) coil pattern 15 is arranged on 7 to constitute an FG sensor.

As another example, a slice coil or a sheet coil may be used. FIG. 8 shows an example of a slice coil described in JP-A-61-73552. The coil 21 and the FG coil 22 are integrated by molding and then sliced as shown by a dotted line. Is done. On the other hand, the sheet coil is formed by patterning the coil by plating or etching, forming a multilayer by the required number of turns of the coil,
It is formed by plating a coil pattern.

[0004]

When a coil of a general surface-facing motor as shown in FIG. 7 is formed, a magnet wire to be wound has a round cross-sectional shape, and when wound, a gap is generated between the magnet wires. Therefore, there are drawbacks such as a low space factor of the coil and difficulty in connecting the winding terminal to the stator substrate .

In the case of a slice coil as shown in FIG. 8, the space factor of the coil is high, but since the terminals of the coil are only on the front and back surfaces, when soldering to the stator substrate, the connection portion is not visible and the connection is difficult. . In addition, when integrally molded with a mold, it is difficult to accurately position the FG pattern 22 on the molding die, and there is a disadvantage that the roundness and the coaxiality with respect to the center axis cannot be easily obtained. In the case of a sheet coil, the space factor of the coil is low (about 50%) and sufficient motor performance
It has the disadvantage of not being able to obtain performance .

SUMMARY OF THE INVENTION The present invention has been made to solve such a problem, and secures a space factor of 80% or more of a coil, which affects the performance of a motor, and facilitates the arrangement and connection of the coil. It is another object of the present invention to provide a thin coil which facilitates the arrangement and connection of the FG pattern.

[0007]

According to the first aspect of the present invention,
A plurality of recesses for inserting arranged a plurality of coils on a substrate made of molding resin is formed Rutotomoni, a inner portion of the recess
A first terminal is formed at a position corresponding to the inner terminal of the coil.
At the position corresponding to the outer terminal of the coil.
A terminal is formed, the first terminal and the second terminal
Is connected to a wiring pattern, and a coil is inserted and arranged in each of the concave portions, and is connected to an inner terminal of the coil and a third terminal.
1 terminal and an outer terminal of the coil.
And the second terminal are connected . The coil is formed by cutting a copper foil wound through an insulating layer into a predetermined thickness, and is formed on the inner peripheral surface of the coil.
Forms the inner terminal may be formed outside terminal on the outer peripheral surface. This coil is inserted into the recess of the substrate and integrated with the substrate, and at least one end face has a frequency generator.
A coil pattern may be formed .

[0008]

By simply inserting the coils into the plurality of concave portions of the substrate made of a molding resin, the coils can be accurately and reliably arranged at predetermined positions. The copper foil wound through the insulating layer is cut into a circle, the inner terminal is formed on the inner peripheral surface, the coil having the outer terminal is formed on the outer peripheral surface, and the pattern for connection is disposed in the concave portion of the molded resin stator substrate. By arranging and integrating the coils, a thin coil having a high space factor can be obtained, and the connection between the terminals of the coil and the pattern on the substrate is also facilitated.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of a thin coil according to the present invention will be described below with reference to the drawings. First, an example of a method for manufacturing a single coil will be described. In FIG. 1, a copper foil 2 coated with an insulating resin on one side is wound around a core 1 with an adhesive interposed therebetween. After the adhesive between the layers of the wound copper foil 2 is cured, the core 1 is pulled out and sliced at a predetermined width (0.4 to 1 mm) to form the coil 3 as shown in FIG. The coil 3 formed by this method is thin and has a high space factor.

Next, an example of a molded resin substrate used in the present invention will be described. In FIG. 3, concave portions 4 are formed at a plurality of locations at regular intervals in the circumferential direction on an upper surface side of an injection molded substrate (hereinafter, simply referred to as “substrate”) 8 formed of a molding resin. At the portion, a joining land 6 protruding so as to face the inner peripheral surface of the coil 3 is formed. The coil 3 sliced with the above-mentioned predetermined width is attached to each recess 4 by a method such as bonding, press fitting, or the like.

Since the coil 3 described with reference to FIGS. 1 and 2 is formed by winding the copper foil 2, the terminals are located on the side surface of the central hole and the outer peripheral surface. Therefore, when the coil 3 is mounted on the injection-molded substrate 8 and connected, the coil 3
Is formed on the substrate 8 in advance. That is, when the coil 3 is inserted and arranged in the recess 4 on the substrate 8, the winding end portion of the outer peripheral surface of the coil 3
(Outer terminal) is in contact with the outer peripheral surface of the concave portion 4 and the coil 3
Winding beginning portion (inner end side of the center hole portion (inner peripheral surface) of the
) Comes into contact with the joint land 6 projecting from the bottom surface of the concave portion 4.
Therefore, as shown in FIG.
When the terminal of the connection pattern 7 is
Is formed so as to come on the outer peripheral surface of the base and the joining land 6. In FIG. 4, reference numeral 7 a denotes a terminal (first terminal) of the connection pattern 7 formed on the joining land 6, and 7 b denotes a terminal (second terminal) of the connection pattern 7 formed on the outer peripheral surface of the concave portion 4 .
Terminals) .

With such a connection pattern, the winding of the coil 3 can be started only by fitting the coil 3 into the recess .
Side terminal) comes into contact with the terminal 7a (first terminal) and the end of winding of the coil 3 (outer terminal) comes into contact with the terminal 7b (second terminal). After the coil 3 is inserted and arranged in the recess 4, the connection of the coil 3 is completed only by performing reflow soldering.
There is no troublesome connection like a conventional slice coil. FIG. 5 shows the appearance of the thin coil made as described above. According to the connection pattern shown in FIG. 4, the six coils 3 are connected in a three-phase Y-shape.

On the other hand, as shown in FIG. 6, after the coil 3 is inserted and arranged in the substrate 8, the FG coil pattern 12 and the PG coil pattern are formed on the back surface of the substrate 8 using an Ag or Cu paste.
To print the over down. Since the FG coil pattern 12 can be formed with reference to, for example, the center hole of the substrate 3, it is easy to obtain the roundness and the coaxiality with respect to the inner diameter of the FG coil pattern 12, and the FG coil pattern 12 is highly accurate. Twelve are possible. A coil power supply terminal 10 for external connection is provided on the outer peripheral side surface of the injection molding resin 3.
The FG output terminal 9 is provided by two lead frames, plating, or the like.

The thin coil made as described above is
The rotor magnet and the rotor integrated therewith can be rotated by switching the energization of each coil 3 according to the rotational position of the rotor magnet. Energization of each coil 3 is performed via a power supply terminal 10. The FG coil pattern 12 generates a signal having a frequency corresponding to the rotation speed of the rotor, and this signal is output from the FG output terminal 9 and used for rotation speed control and the like.

According to the embodiment described above, the coil 3 is positioned only by inserting and arranging the coil 3 in the concave portion 4 of the substrate 8 made of a molding resin .
Side terminal) and winding end (outer terminal) the terminal 7a of the coil wire connection pattern 7 (first terminal), 7b (second end
Since the coils 3 can be opposed to each other, the arrangement and connection of the coils 3 can be simplified, and the coils 3 can be positioned accurately and reliably. In the state where the coil 3 is integrated with the substrate 8, the FG coil pattern 1
2 can be printed on the substrate 8, and the surface of the substrate 8 on which the FG coil pattern 12 is printed is a flat surface, so that the FG coil pattern 12 can be easily formed.
The positional accuracy, roundness and coaxiality can be improved.

If another motor component is mounted on an injection molded board, the board itself can be used as a stator board.

[0017]

According to the present invention, the coil can be positioned only by inserting and arranging the coil in the concave portion of the substrate made of molding resin, and the beginning and end of winding of the coil can be opposed to the coil connection pattern. Therefore, the arrangement and connection of the coils are simple, and the coils can be accurately and reliably positioned. Also,
Since the FG coil pattern can be printed on the substrate while the coil is integrated with the substrate, the FG coil pattern can be easily formed, and the positional accuracy, roundness and coaxiality can be improved. it can.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an example of a coil forming process applicable to the present invention.

FIG. 2 is a perspective view showing another step following the coil forming step.

FIG. 3 is a perspective view showing an example of an injection molded substrate applicable to the present invention.

FIG. 4 is a plan view of the injection molded substrate.

FIG. 5 is a perspective view showing an embodiment of a thin coil according to the present invention.

FIG. 6 is a perspective view showing the thin coil, which is turned upside down;

FIG. 7 is a plan view showing an example of a conventional thin coil.

FIG. 8 is a perspective view showing an example of a slice coil which is a kind of a conventional thin coil.

[Explanation of symbols]

 2 Copper foil 3 Coil 4 Concave section 7 Connection pattern 8 Board

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor, Hisashimasa Kobayashi 14-888, Ako, Komagane-shi, Nagano Co., Ltd. In the Komagane factory of Sankyo Seiki Seisakusho Co., Ltd.

Claims (3)

(57) [Claims] 1. A plurality of recesses for inserting arranged a plurality of coils on a substrate made of molding resin is formed Rutotomoni, a inner portion of the recess in a position corresponding to the inner terminal of the coil
A first terminal is formed and corresponds to the outer terminal of the coil.
A second terminal is formed at a position corresponding to the first terminal and the second terminal.
A wiring pattern is connected to the second terminal.
Then , a coil is inserted and arranged in each of the concave portions,
And the first terminal is connected to the inner terminal of the
A thin coil wherein an outer terminal of the coil and a second terminal are connected . 2. The coil is formed by cutting a copper foil wound through an insulating layer into a predetermined thickness, and has an inner peripheral surface on an inner peripheral surface.
It has terminals, thin coil of claim 1 having an outer terminal to the outer peripheral surface. 3. A coil is inserted into each recess of the substrate to be integrated with the substrate, and at least one end face has a frequency.
2. The thin coil according to claim 1, wherein a coil pattern of several generators is formed .