Coil and method for forming a coil

Patent metadata

Field	Value
Publication number	US-10403430-B2
Application number	US-201113315067-A
Country	US
Kind code	B2
Filing date	Dec 8, 2011
Priority date	May 11, 2006
Publication date	Sep 3, 2019
Grant date	Sep 3, 2019

Abstract

A reactor coil includes first and second coil elements each formed by edgewise and rectangular winding of one piece of rectangular wire rod in a manner in which the wound rectangular wire rod is stacked rectangularly and cylindrically and, at a winding terminating end point of the first coil element, the rectangular wire rod is bent approximately 90 degrees in a direction opposite to the winding direction of the first coil element so that the rectangular wire rod is stacked in a direction opposite to the stacking direction of the first coil element and is wound edgewisely and rectangularly in a direction opposite to the winding direction of the first coil element to form the second coil element and, as a result, the first coil element and second coil element are aligned in parallel to each other in a continuous state.

First claim

What is claimed:

1. A coil, comprising:
first and second coil elements both of which are formed by one piece of rectangular wire rod and each of which is wound rectangularly in an edgewise manner and stacked cylindrically,
wherein a winding terminating end point of said first coil element extends to a reverse bent portion being bent approximately 90 degrees in a direction opposite to a winding direction of said first coil element,
wherein said second coil element includes an offset portion that is extended from said reverse bent portion in a winding direction of said second coil element and that is offset from one side of said second coil element in a direction perpendicular to a direction which the offset portion extends,
wherein a winding terminating end point of said second coil element is connected to said reverse bent portion in a same flat plane that continuously extends from said first coil element to said second coil element,
wherein, in a plan view, in the direction perpendicular to the direction which the offset portion extends, a part of the offset portion overlaps with remaining portions of the wire rod of said second coil element, and
wherein, in the plan view, in the direction perpendicular to the direction which the offset portion extends, another part of the offset portion is exposed outside of an entirety of the remaining portions of the wire rod of said second coil element.

2. A coil as claimed in claim 1 , said coil being for use in a reactor, wherein said coil is contained in a thermally conductive case which includes an inner surface containing said coil, said inner surface comprising substantially a plane surface.

3. A coil as claimed in claim 2 , wherein an insulation sheet is placed between the reactor and the thermally conductive case.

4. A coil as claimed in claim 1 , wherein said coil is contained in a thermally conductive case which includes an inner surface containing said coil, said inner surface comprising substantially a plane surface.

5. A coil as claimed in claim 4 , wherein bottom faces of said first coil element and said second coil element are co-planes and are in contact with the thermally conductive case.

6. A reactor comprising said coil as claimed in claim 1 , wherein said coil is contained in a thermally conductive case which includes an inner surface containing said coil, said inner surface comprising substantially a plane surface.

7. A reactor as claimed in claim 6 , wherein an insulation sheet is placed between the reactor and the thermally conductive case.

8. A coil as claimed in claim 1 , wherein said first coil element and said second coil element are aligned in parallel to each other continuously.

9. A coil as claimed in claim 8 , wherein the winding direction of said first coil element is reversed from a winding direction of said second coil element.

10. A coil as claimed in claim 9 , wherein said rectangular wire rod is stacked in a direction opposite to a stacking direction of said first coil element and is wound in the direction opposite to the winding direction of said first coil element to form the second coil element.

11. A coil as claimed in claim 10 , further comprising:
a lead portion of said first coil element and a lead portion of said second coil element,
wherein the lead portion of said first coil element and the lead portion of said second coil element are placed on a same side of each of the coil elements.

12. A coil as claimed in claim 1 , further comprising:
a lead portion of said first coil element and a lead portion of said second coil element,
wherein the lead portion of said first coil element and the lead portion of said second coil element are placed on a same side of each of the coil elements.

13. A coil as claimed in claim 1 , wherein a coupling between said first coil element and said second coil element is by directly bending the rectangular wire rod.

14. A coil as claimed in claim 1 , wherein a coupling between said first coil element and said second coil element is only by bending the rectangular wire rod.

15. A coil as claimed in claim 1 , wherein the same flat plane continuously extends from an upper surface of said second coil element to an upper surface of said first coil element.

16. A coil as claimed in claim 1 , wherein the offset portion is offset from only said second coil element.

17. A coil as claimed in claim 1 , wherein the offset portion extends in the same flat plane that continuously extends from said first coil element to said second coil element.

18. A coil, comprising:
first and second coil elements both of which are formed by one piece of rectangular wire rod and each of which is wound rectangularly in an edgewise manner and stacked cylindrically,
wherein a winding terminating end point of said first coil element extends to a revere bent portion being bent approximately 90 degrees in a direction opposite to a winding direction of said first coil element,
wherein said second coil element includes an offset portion that is extended from said reverse bent portion in a winding direction of said second coil element and that is offset from one side of said second coil element in a direction perpendicular to a direction which the offset portion extends,
wherein a winding terminating end point said second coil element is connected to said reverse bent portion in a same flat plane that continuously extends from said first coil element to said second coil element, and
wherein, in the direction perpendicular to the direction which the offset portion extends, a distance between a centerline of said second coil element and an outer edge of the offset portion is more than a distance between the centerline of said second coil element and an outer edge of a layer of the wire rod of said second coil element that is located adjacent to, and below, the offset portion, an inner edge of the offset portion overlapping with the layer of the wire rod of said second coil element.

Assignees

• Hasu Masatoshi
• Hattori Kaoru
• Nakatsu Ryo
• Urano Sei
• Maeno Kensuke
• Tamura Seisakusho Kk
• Tamura Fa System Corp

Inventors

• Hasu Masatoshi
• Hattori Kaoru
• Nakatsu Ryo
• Urano Sei
• Maeno Kensuke

Classifications

• H01F41/061

  Winding flat conductive wires or sheets · CPC title

• H01F27/325

  Coil bobbins (formers for coils in general H01F5/02) · CPC title

• H01F27/2847 Primary

  Sheets; Strips (H01F27/2866 takes precedence) · CPC title

• H01F27/022

  Encapsulation · CPC title

• H01F3/14

  Constrictions; Gaps, e.g. air-gaps (in magnetic shunt paths H01F3/12) · CPC title