Coil and method for forming a coil

Patent metadata

Field	Value
Publication number	US-10964470-B2
Application number	US-201916553873-A
Country	US
Kind code	B2
Filing date	Aug 28, 2019
Priority date	May 11, 2006
Publication date	Mar 30, 2021
Grant date	Mar 30, 2021

Abstract

A coil includes first and second coil elements both of which are formed by feeding one piece of a rectangular wire rod by a predetermined amount and winding rectangularly in an edgewise manner using winding heads, the first and second coil elements being wound in opposite directions from each other. A winding terminating end point of the first coil element is bent approximately 90 degrees in a direction opposite to a winding direction of the first coil element, and is connected to a winding terminating end point of the second coil element in a same flat plane. The second coil element includes an offset portion of the rectangular wire rod that is offset in a plan view from a side of the second coil element.

First claim

What is claimed is:

1. A coil, comprising:
first and second coil elements both of which are formed by feeding one piece of a rectangular wire rod by a predetermined amount and winding rectangularly in an edgewise manner using winding heads, the first and second coil elements being wound in opposite directions from each other,
wherein a winding terminating end point of the first coil element is bent approximately 90 degrees in a direction opposite to a winding direction of the first coil element, and is connected to a winding terminating end point of the second coil element in a same flat plane,
wherein the second coil element includes an offset portion of the rectangular wire rod that is offset, in a plan view, from a side of the second coil element,
wherein the offset portion is formed by feeding an offset amount F in addition to the predetermined amount at half around before finishing winding the second coil element, and then finishing winding the second coil element, and
wherein the offset amount F is calculated from an equation (1),
F =( L 1− a )/2+( b+r )  (1)

wherein:
“L1” is a distance, in the plan view, between a centerline of a side of the first coil element and a centerline of the side of the second coil element facing each other at half around before finishing winding the second coil element;
“a” is a length of the side of the first coil element;
“b” is a width of the rectangular wire rod; and
“r” is a diameter of the winding heads.

2. A coil as claimed in claim 1 , the coil being configured to be used in a reactor, wherein the coil is contained in a thermally conductive case which includes an inner surface containing the coil, the 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 the coil is contained in a thermally conductive case which includes an inner surface containing the coil, the inner surface comprising substantially a plane surface.

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

6. A reactor comprising the coil as claimed in claim 1 , wherein the coil is contained in a thermally conductive case which includes an inner surface containing the coil, the 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 the first coil element and the second coil element are aligned in parallel to each other continuously.

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

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

11. A coil as claimed in claim 10 , further comprising:
a lead portion of the first coil element and a lead portion of the second coil element,
wherein the lead portion of the first coil element and the lead portion of the 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 the first coil element and a lead portion of the second coil element,
wherein the lead portion of the first coil element and the lead portion of the 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 the first coil element and the second coil element is by directly bending the rectangular wire rod.

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

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

Assignees

• Tamura Seisakusho Kk

Inventors

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

Classifications

• H01F30/00

  Fixed transformers not covered by group H01F19/00 · CPC title

• H01F27/28 Primary

  Coils; Windings; Conductive connections · CPC title

• H01F41/06

  Coil winding · CPC title

• H01F41/061

  Winding flat conductive wires or sheets · CPC title

• Y10T29/49069

  Data storage inductor or core · CPC title