Coil and manufacturing method for same, and reactor

Patent metadata

Field	Value
Publication number	US-9514878-B2
Application number	US-201414550416-A
Country	US
Kind code	B2
Filing date	Nov 21, 2014
Priority date	Nov 22, 2013
Publication date	Dec 6, 2016
Grant date	Dec 6, 2016

Abstract

A coil includes a coil unit provided with a wire and a self-melting layer formed on surfaces of the wire, and a resin member affixed to the wire. The wire is adhered and affixed to the resin member by the self-melting layer.

First claim

What is claimed is:

1. A coil comprises:
a coil unit provided with a wire,
a self-melting layer formed on surfaces of the wire, and
a resin member affixed to the wire, wherein
the wire is a flat wire,
the coil unit is an edgewise coil in which the flat wire is wound,
the resin member is mounted on an axial-direction end of the coil unit,
pressure is applied to the coil unit in the axial direction of the coil unit with the resin member mounted thereon and with the resin member interposed therebetween,
the self-melting layer on the surfaces of the flat wire is heated and melts to adhere to adjacent segments of the wound flat wire,
a protruding portion that protrudes from the surface of the flat wire is formed on at least one part of the coil unit, and
a portion of the protruding portion is adhered to an adjacent segment of the flat wire by the self-melting layer.

2. The coil as claimed in claim 1 , wherein the resin member is mounted on both ends of the coil unit.

3. The coil as claimed in claim 1 , wherein the protruding portion is crushed by pressure being applied in the axial direction of the coil unit after the flat wire is wound.

4. The coil as claimed in claim 1 , wherein the protruding portion is formed on at least one part of an inner circumference of bends in the coil unit, and the protruding portion is crushed by pressure being applied in the axial direction of the coil unit after the flat wire is wound.

5. The coil as claimed in claim 1 , wherein
the flat wire has a flat surface,
the coil unit is formed by winding the flat wire such that the flat surfaces confront one another, and
adjacent segments of the flat wire are adhered on at least part of the flat surfaces by the self-melting layer.

6. The coil as claimed in claim 1 , wherein the resin member has a through portion for a connection terminal protruding from an end portion of the coil unit.

7. The coil as claimed in claim 1 , wherein the resin member has a affixing portion for a core inserted into the coil unit.

8. A reactor comprising a core and the coil as claimed in claim 1 , wherein
the core is embedded in the resin member, and
a positioning portion that positions an end of the coil unit is provided to a surface of the resin member in which the core is embedded.

9. The reactor as claimed in claim 8 , wherein
the self-melting layer at the end of the wire is adhered to the positioning portion and the wire of the coil unit is affixed to the resin member.

10. A reactor comprising a core and the coil as claimed in claim 1 , wherein
the core is embedded in the resin member, and
the end face of the coil unit is adhered to the resin member by the self-melting layer.

Assignees

• Tamura Seisakusho Kk

Inventors

• Nakatsu Ryo
• Ninomiya Toshikazu
• Maeno Kensuke
• Yamada Masashi
• Tanaka Ryotaro

Classifications

• H01F27/323 Primary

  Insulation between winding turns, between winding layers · CPC title

• H01F2027/406

  Temperature sensor or protection · CPC title

• H01F27/402

  Association of measuring or protective means · CPC title

• H01F27/2852

  Construction of conductive connections, of leads · CPC title

• H01F27/306

  Fastening or mounting coils or windings on core, casing or other support · CPC title