Search

JP-2026075211-A - Edgewise coil and method for manufacturing edgewise coil

JP2026075211AJP 2026075211 AJP2026075211 AJP 2026075211AJP-2026075211-A

Abstract

[Problem] To improve the processability when bending flat wire. [Solution] The edgewise coil 20 comprises a first coil portion 22A and a second coil portion 22B formed by bending a flat wire 30. The first coil portion 22A, when viewed in the axial direction, has a plurality of first straight portions 23A and a first bent portion 24A connecting adjacent first straight portions 23A in the circumferential direction, and the first bent portion 24A has a narrow portion 25 with a smaller cross-sectional area than the first straight portions 24A. The second coil portion 22B, when viewed in the axial direction, has a plurality of second straight portions 23B and a second bent portion 24B connecting adjacent second straight portions 23B in the circumferential direction, and the second bent portion 24B has a narrow portion 25 with a smaller cross-sectional area than the second straight portions 24B. [Selection Diagram] Figure 1

Inventors

  • 相澤 武史
  • 鈴木 寛之
  • 日比野 朝人

Assignees

  • 株式会社オートネットワーク技術研究所
  • 住友電装株式会社
  • 住友電気工業株式会社

Dates

Publication Date
20260508
Application Date
20241022

Claims (6)

  1. It has a coil section formed by bending a flat wire, The coil portion, when viewed in the axial direction, has a plurality of straight sections and bent sections that connect adjacent straight sections in the circumferential direction. The bent portion is an edgewise coil having a narrower width with a smaller cross-sectional area than the straight portion.
  2. The edgewise coil according to claim 1, wherein a pair of opposing surfaces facing each other in the circumferential direction of the coil portion are formed in the region of the bent portion from the narrow portion to the inner circumferential edge of the coil portion.
  3. The edgewise coil according to claim 2, wherein the pair of opposing surfaces are in contact with each other.
  4. The edgewise coil according to claim 3, wherein the pair of opposing surfaces are in surface contact.
  5. A method for manufacturing the edgewise coil according to claim 1, In the state in which the rectangular cross-section is in a straight line, a plurality of narrow sections are formed by forming a plurality of notches on the side edge along the length direction of the rectangular cross-section, A method for manufacturing an edgewise coil, comprising forming the bent portion by bending the aforementioned rectangular wire at the narrow portion.
  6. The method for manufacturing an edgewise coil according to claim 5, wherein the flat wire is bent so that the notch closes in the narrow portion.

Description

This disclosure relates to edgewise coils and methods for manufacturing edgewise coils. Patent Document 1 discloses an edgewise coil constructed by spirally winding a rectangular wire with a rectangular cross-section. The coil portion of the edgewise coil is shaped like a square when viewed in the axial direction. Japanese Patent Publication No. 2019-021796 Figure 1 is a perspective view of the noise filter of Example 1.Figure 2 is a plan view of the noise filter.Figure 3 is a front view of the noise filter.Figure 4 is a left side view of the noise filter.Figure 5 is a cross-sectional view taken along the line X-X in Figure 2.Figure 6 is a cross-sectional view taken along the line Y-Y in Figure 3.Figure 7 is a plan view showing the manufacturing process of edgewise coils. [Description of Embodiments in this Disclosure] First, embodiments of this disclosure will be listed and described. Any combination of the following embodiments, in a manner that does not create a contradiction, is also included as a form for carrying out the invention. The edgewise coil of this disclosure is (1) The present invention provides a coil portion formed by bending a flat wire, wherein the coil portion, when viewed in the axial direction, has a plurality of straight sections and a bent section connecting adjacent straight sections in the circumferential direction, and the bent section has a narrower width with a smaller cross-sectional area than the straight sections. According to the present invention, in the process of bending a flat wire so as to bend the plate thickness surface in the axial direction, there is a concern that stress concentration or abnormal deformation may occur at the bent section. However, since the bent section has a narrower width with a smaller cross-sectional area than the straight sections, the stress generated at the bent section during bending is small, and there is no risk of abnormal deformation at the bent section. Therefore, it is possible to improve the processability when bending a flat wire into a rectangular tube shape. (2) In (1), it is preferable that a pair of opposing surfaces facing each other in the circumferential direction of the coil portion are formed in the region of the bent portion from the narrow portion to the inner circumferential edge of the coil portion. With this configuration, at the inner circumferential edge of the bent portion, two straight portions are arranged in close proximity in the circumferential direction, thus preventing the magnetic field strength at the bent portion from becoming extremely low. (3) In (2), it is preferable that the pair of opposing surfaces are in contact with each other. With this configuration, the pair of opposing surfaces are in contact in the circumferential direction, thus stabilizing the shape of the bent portion. (4) In (3), it is preferable that the pair of opposing surfaces are in surface contact. With this configuration, since the cross-sectional area of the narrow section is smaller than that of the straight section, there is a concern that the electrical resistance may increase in the bent section. However, by having the pair of opposing surfaces in surface contact, the contact area between the two opposing surfaces increases, thus avoiding an increase in electrical resistance in the bent section. (5) The method for manufacturing the edgewise coil described in (1) involves forming multiple narrow sections by creating multiple notches along the side edges of the rectangular wire in a straight state, and then forming the bent section by bending the rectangular wire at the narrow sections. According to this manufacturing method, by forming multiple narrow sections in the straight rectangular wire beforehand, the straight and bent sections of the coil can be formed continuously. In (6) and (5), it is preferable to bend the rectangular wire so that the notch closes in the narrow portion. This manufacturing method allows for the formation of a bent portion having a pair of opposing surfaces on the inner circumference side of the narrow portion. [Details of the embodiments of this disclosure] [Example 1] A noise filter 1 of Embodiment 1, embodying the present disclosure, will be described with reference to Figures 1 to 7. The present invention is not limited to these examples, but is shown in the claims, and all modifications within the meaning and scope of equivalence to the claims are included. In Embodiment 1, the front-to-back direction is defined as the F direction in Figures 1, 2, 4, and 6. The up-and-down direction is defined as the H direction in Figures 1, 3 to 5. The left-to-right direction is defined as the L direction in Figures 1 to 3, 5, and 6. The up-and-down direction and the axial direction are used synonymously. The noise filter 1 of this embodiment 1 comprises one core 10 and one edgewise coil 20. The core 10 is made of a magnetic material such as iron, or a material containing a magnetic material. The core 10 has a