阅读说明：本技术 一种线圈绕制模板及超小体积线圈成型方法 (Coil winding template and ultra-small volume coil forming method ) 是由 胡博 张小龙 龚建军 魏花 陈顺新 田露 许志城 于 2021-08-03 设计创作，主要内容包括：本发明提供了一种线圈绕制模板及超小体积线圈成型方法,线圈绕制模板,包括线圈骨架、夹持结构和整形套,所述线圈骨架下部固设有夹持结构,所述整形套套设在线圈骨架外,所述线圈骨架上开设有线圈绕制槽,所述线圈骨架采用可溶解材料。本发明线圈骨架采用可溶解材料,线圈骨架在溶解溶液中溶解后,避免脱模过程中铜线被拉断、蹭破绝缘层,以及脱模过程中常发生夹持变形、拖拽变形、金属零件间的间隙常将绕组铜线卡住,造成铜线被夹伤、夹断等情况。该线圈绕制模板首先采用胶粘剂对线圈进行定型,增加线圈自身强度,再通过整形套对绕制的线圈整形进行整形,可以实现超小体积(低至2mm直径)下的线圈高精度成型。(The invention provides a coil winding template and a forming method of an ultra-small volume coil. The coil framework is made of a soluble material, so that after the coil framework is dissolved in a dissolving solution, the situations that a copper wire is broken and an insulating layer is scratched in a demolding process, and the winding copper wire is clamped by a gap between metal parts due to clamping deformation, dragging deformation and clamping breakage and the like which are frequently generated in the demolding process are avoided. The coil winding template firstly adopts the adhesive to shape the coil, the strength of the coil is increased, and then the shaping sleeve shapes the wound coil, so that the high-precision forming of the coil with ultra-small volume (as low as 2mm in diameter) can be realized.)

1. A coil winding template is characterized in that: the coil winding device comprises a coil framework, a clamping structure and a shaping sleeve, wherein the clamping structure is fixedly arranged on the lower portion of the coil framework, the shaping sleeve is sleeved outside the coil framework, a coil winding groove is formed in the coil framework, and the coil framework is made of a soluble material.

2. A coil winding form as claimed in claim 1, wherein: the coil winding grooves are multiple and are arranged from top to bottom.

3. A coil winding form as claimed in claim 1, wherein: the dissolvable material is polysulfone material, and the shaping sleeve is made of metal material.

4. A coil winding form as claimed in claim 2, wherein: a connecting wire passing groove is arranged between every two adjacent coil winding grooves, and a wire outlet groove is formed at the bottom end of the coil winding groove at the lowest end.

5. A coil winding form as claimed in claim 2, wherein: the interval between two adjacent coil winding grooves is 1-2 mm.

6. A method for forming a coil with an ultra-small volume by using the coil winding template as claimed in any one of claims 1 to 5, which is characterized by comprising the following steps:

step 1) fixing a coil winding template on a winding machine through a clamping structure, winding a copper wire in a coil winding groove of a coil framework, and uniformly coating an adhesive on the copper wire during winding until the number of turns is regulated to form a coil;

step 2) sleeving a shaping sleeve on the coil framework to shape the formed coil;

step 3) placing the plastic sleeve into a drying oven at 50-70 ℃ for 0.5-1h, then taking down the plastic sleeve, and then placing the plastic sleeve into the drying oven for at least 4h for curing;

and 4) placing the coil into the dissolving solution, standing for 4-6h, taking out, and completely dissolving the coil framework to obtain the formed coil.

7. The method of claim 6, wherein the method comprises: the adhesive is an epoxy adhesive DG-2; the coil skeleton is made of polysulfone material, and the dissolving solution is trichloromethane solution.

8. The method of claim 6, wherein the method comprises: the external diameter of the ultra-small volume coil is not more than 2mm, and the internal diameter is not more than 1 mm.

Technical Field

The invention belongs to the technical field of manufacturing processes of motor coils, and particularly relates to a coil winding template and a forming method of an ultra-small-volume coil.

Background

For a laser system for satellite communication, a light path adjusting device is required to be small in size, light in weight, and controllable with high accuracy. For this reason, it is proposed in some satellite general unit to use an optical path adjusting mechanism with an outer diameter of only 5mm to replace the existing large-size laser mirror, the optical path adjusting mechanism mainly comprises a lens with an outer diameter of 5mm and 4 voice coil motors with an outer diameter of 2.5mm and a height of 3mm, and the deflection action of the lens is realized through the cooperation of actuating modes among the 4 voice coil motors. Wherein the coil that voice coil motor used is 2 groups interval 1mm distance, and external diameter 2mm, internal diameter 1mm, high 1 mm's hollow copper line coiling coil is constituteed, and this coil needs to have certain intensity in order to keep self shape.

The current coil forming technology generally uses a mode of integrally demoulding after winding on a winding framework. After the copper wire is evenly coated with the adhesive, the copper wire is wound in a gap formed by the winding framework and the gland to form a coil, and the coil is pressed and adjusted by the nut. And after the coil is wound, the coil is taken off from the winding framework to form a usable coil. The above coil forming method is often used in manufacturing common motors, but when applied to coils with ultra-small volume, there are problems including:

(1) The wire diameter used by the coil is usually below 0.1mm, and the copper wire is broken and scratched to break the insulation in the demolding process;

(2) the coil is extremely low in self-curing molding strength, and clamping deformation, dragging deformation and the like are frequently generated in the demolding process;

(3) gaps between metal parts often clamp the winding copper wires, causing the copper wires to be damaged and broken.

Disclosure of Invention

The invention aims to provide a coil winding template, which overcomes the technical problems of winding an ultra-small coil in the prior art.

The invention also aims to provide a method for forming the coil with the ultra-small volume, which realizes high-precision forming of the coil with the ultra-small volume by removing the coil framework.

Therefore, the technical scheme provided by the invention is as follows:

the utility model provides a coil winding template, includes coil skeleton, clamping structure and plastic cover, the clamping structure has set firmly in the coil skeleton lower part, the plastic cover is established outside the coil skeleton, the coil winding groove has been seted up on the coil skeleton, the coil skeleton adopts dissolvable material.

The coil winding grooves are multiple and are arranged from top to bottom.

The dissolvable material is polysulfone material, and the shaping sleeve is made of metal material.

A connecting wire passing groove is arranged between every two adjacent coil winding grooves, and a wire outlet groove is formed at the bottom end of the coil winding groove at the lowest end.

The interval between two adjacent coil winding grooves is 1-2 mm.

A method for forming an ultra-small volume coil adopts a coil winding template and comprises the following steps:

step 1) fixing a coil winding template on a winding machine through a clamping structure, winding a copper wire in a coil winding groove of a coil framework, and uniformly coating an adhesive on the copper wire during winding until the number of turns is regulated to form a coil;

step 2) sleeving a shaping sleeve on the coil framework to shape the formed coil;

step 3) placing the plastic sleeve into a drying oven at 50-70 ℃ for 0.5-1h, then taking down the plastic sleeve, and then placing the plastic sleeve into the drying oven for at least 4h for curing;

and 4) placing the coil into the dissolving solution, standing for 4-6h, taking out, and completely dissolving the coil framework to obtain the formed coil.

The adhesive is an epoxy adhesive DG-2; the coil skeleton is made of polysulfone material, and the dissolving solution is trichloromethane solution.

The external diameter of the ultra-small volume coil is not more than 2mm, and the internal diameter is not more than 1 mm.

The invention has the beneficial effects that:

according to the coil winding template provided by the invention, the coil framework is made of a soluble material, and after the coil framework is dissolved in a dissolving solution, the situations that a copper wire is pulled apart and an insulating layer is scratched in a demolding process, and the winding copper wire is clamped and damaged, is clamped and broken due to clamping deformation, dragging deformation and clamping deformation which often occur in the demolding process and gaps among metal parts often clamp the winding copper wire are avoided.

The coil winding template firstly adopts the adhesive to shape the coil, the strength of the coil is increased, and then the shaping sleeve shapes the wound coil, so that the high-precision forming of the coil with ultra-small volume (as low as 2mm in diameter) can be realized.

The coil winding template has good machinability, simple structure and high machining precision; the organic solvent is fast in dissolving the coil framework, and has no influence on the insulating property and the mechanical property of the coil.

The following will be described in further detail with reference to the accompanying drawings.

Drawings

FIG. 1 is a schematic structural diagram of an embodiment of the present invention;

FIG. 2 is a schematic diagram of a winding process of a coil winding form;

fig. 3 is a schematic diagram of a prior art coil forming technique.

In the figure: 1. a coil bobbin; 2. shaping sleeves; 3. a coil; 4. connecting the wire passing groove; 5. an outlet groove; 6. winding a coil in a slot; 7. a clamping structure; 8. a winding framework 8; 9. a gland; 10. and a nut.

Detailed Description

The following description of the embodiments of the present invention is provided for illustrative purposes, and other advantages and effects of the present invention will become apparent to those skilled in the art from the present disclosure.

The exemplary embodiments of the present invention will now be described with reference to the accompanying drawings, however, the present invention may be embodied in many different forms and is not limited to the embodiments described herein, which are provided for complete and complete disclosure of the present invention and to fully convey the scope of the present invention to those skilled in the art. The terminology used in the exemplary embodiments illustrated in the accompanying drawings is not intended to be limiting of the invention. In the drawings, the same units/elements are denoted by the same reference numerals.

Unless otherwise defined, terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Further, it will be understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense.

Example 1:

this embodiment provides a coil winding template, including coil skeleton 1, clamping structure 7 and plastic cover 2, 1 lower part of coil skeleton has set firmly clamping structure 7, the plastic cover 2 cover is established outside coil skeleton 1, coil winding groove 6 has been seted up on coil skeleton 1, coil skeleton 1 adopts soluble material.

According to the coil winding template provided by the invention, the coil framework 1 is made of a soluble material, and after the coil framework 1 is dissolved in a dissolving solution, the situations that a copper wire is broken and an insulating layer is scratched in a demolding process, and the winding copper wire is clamped and damaged, is clamped and broken due to clamping deformation, dragging deformation and clamping of gaps among metal parts which are often generated in the demolding process are avoided.

Example 2:

on the basis of embodiment 1, this embodiment provides a plurality of coil winding templates, and the coil winding grooves 6 are arranged from top to bottom.

The coil winding template is provided with a plurality of coil winding grooves 6 from top to bottom, a plurality of groups of coils 3 can be wound by one copper wire, and as shown in figures 1 and 2, the distance between the coil winding grooves 6 is consistent with the distance between two groups of coils 3 used by a voice coil motor. Coil 3 that voice coil motor used is 2 groups interval 1mm distance, external diameter 2mm, internal diameter 1mm, and high 1 mm's hollow copper wire coiling coil 3 constitutes, and this coil 3 needs have certain intensity in order to keep self shape.

Example 3:

on the basis of embodiment 1, this embodiment provides a coil winding template, the dissolvable material is polysulfone material, and the shaping sleeve 2 is made of metal material.

The coil framework 1 is made of organic materials polysulfone, and the coil framework 1 is removed through an organic solvent trichloromethane, so that the coil 3 with an ultra-small volume is formed in a high-precision mode.

Example 4:

on the basis of embodiment 2, this embodiment provides a coil winding template, and a connecting wire passing groove 4 is provided between two adjacent coil winding grooves 6, and a wire outlet groove 5 is provided at the bottom end of the coil winding groove 6 at the lowermost end.

In this embodiment, two coil winding grooves 6 are provided, and two groups of coils 3 can be wound successively. As shown in figure 1, when two groups of coils 3 are wound, adhesive is uniformly coated on the wound copper wires, one ends of the wound copper wires penetrate through a wire outlet groove 5 and a wire passing groove 4, the coils 3 are wound in an upper coil winding groove 6, after the required number of turns of the coils are wound, the coils 3 are wound in a lower coil winding groove 6, after the two groups of coils 3 are wound, a shaping sleeve 2 is sleeved into the coils 3 for shaping, after the glue solution is cleared and overflowed, the coils are placed in a 60 ℃ oven for half an hour, then the shaping sleeve 2 is taken down, and then the coils are placed in the 60 ℃ oven for at least 4 hours and then cured. And (3) placing the solidified assembly of the coil framework 1 and the coil 3 into a trichloromethane solution, standing for 4 to 6 hours, taking out, completely dissolving the coil framework 1, and forming the two groups of coils 3 to obtain two integrated groups of coils 3.

Example 5:

on the basis of embodiment 2, this embodiment provides a coil winding template, and the interval between two adjacent coil winding grooves 6 is 1-2 mm.

The interval between two adjacent coil winding grooves 6 is consistent with the required interval of a plurality of groups of coils 3. Fig. 1 shows a typical structure of a coil winding template, wherein a coil frame 1 is made of polysulfone material and is used for winding 2 groups of hollow coils 3 with a distance of 1mm, an outer diameter of 2mm and an inner diameter of 1 mm. The connecting wire passing grooves 4 are arranged between the 2 groups of coil winding grooves 6, the bottom of each coil winding groove 6 is provided with a wire outlet groove 5 of the coil 3, and the lower part of the coil framework 1 is provided with a winding machine clamping part.

Example 6:

the embodiment provides a method for forming a coil 3 with an ultra-small volume, which adopts a coil winding template and comprises the following steps:

step 1) fixing a coil winding template on a winding machine through a clamping structure 7, winding a copper wire in a coil winding groove 6 of a coil framework 1, and uniformly coating an adhesive on the copper wire until the number of turns is regulated to form a coil 3 during winding;

step 2) sleeving the shaping sleeve 2 on the coil framework 1 to shape the formed coil 3;

step 3), putting the plastic sleeve into a drying oven at 50-70 ℃ for 0.5-1h, then taking down the plastic sleeve 2, and then, standing the plastic sleeve in the drying oven for at least 4h and then curing the plastic sleeve;

And 4) placing the coil skeleton into a dissolving solution, standing for 4-6h, taking out, and completely dissolving the coil skeleton 1 to obtain the formed coil 3.

The existing coil 3 forming technology is as shown in fig. 3, wherein a copper wire is uniformly coated with an adhesive and then wound in a gap formed by a winding frame and a gland 9 to form a coil 3, and the position of the coil 3 is pressed and adjusted by a nut 10. And after the coil 3 is wound, taking off the coil 3 from the winding framework to form the usable coil 3. The above coil 3 forming method is often used in manufacturing common motors, but when the coil 3 forming method is applied to an ultra-small volume coil 3, a lot of problems exist. Compared with the prior coil 3 forming technology, the invention solves the following problems:

(1) the wire diameter used by the coil 3 is usually below 0.1mm, and the copper wire is broken and scratched to break the insulation in the demolding process;

(2) the coil 3 has extremely low self-curing molding strength, and clamping deformation, dragging deformation and the like often occur in the demolding process;

(3) gaps between metal parts often clamp the winding copper wires, causing the copper wires to be damaged and broken.

Example 7:

on the basis of embodiment 6, the present embodiment provides a method for forming an ultra-small volume coil 3, where the adhesive is an epoxy adhesive DG-2; the coil framework 1 is made of polysulfone material, and the dissolving solution is trichloromethane solution.

The invention can realize the high-precision forming of the ultra-small coil 3 with the diameter as low as 2 mm; the coil winding template has good machinability, simple structure and high machining precision; the organic solvent dissolves the coil framework 1 quickly, and has no influence on the insulating property and the mechanical property of the coil 3.

Example 8:

on the basis of embodiment 6, this embodiment provides a method for forming an ultra-small volume coil 3, where the outer diameter of the ultra-small volume coil 3 is not greater than 2mm, and the inner diameter is not greater than 1 mm.

In this embodiment, as shown in fig. 1, the diameter of the clamping structure 7 is 4mm, the diameter of the coil bobbin 1 is 2mm, the diameter of the coil winding groove 6 is 1mm, the distance between the two groups of coil winding grooves 6 is 1mm, and the height of the coil winding groove 6 is 1 mm.

The coil framework 1 is made of a dissolvable material, has certain strength and good processing performance. The coil 3 is formed by bonding copper wires together by an adhesive, and the shaping sleeve 2 is used for fixing the shape of the coil 3. The sizing sleeve 2 is removed before the adhesive is fully applied and the bobbin 1 is dissolved using a solvent, resulting in a usable coil 3. The dissolving method of the invention removes the coil framework 1, is suitable for molding the coil 3 with the ultra-small volume of which the outer diameter phi is less than 5mm of the coil winding template, and provides the coil 3 which can be used for an ultra-small motor.

The above examples are merely illustrative of the present invention and should not be construed as limiting the scope of the invention, which is intended to be covered by the claims and any design similar or equivalent to the scope of the invention.