Process for the preparation of coil for electric appliance and coil for electric appliance

• US 20050046538A1
• Filed: 08/25/2004
• Published: 03/03/2005
• Est. Priority Date: 08/27/2003
• Status: Active Grant

• Current Assignee: Fuji Jukogyo KK (Subaru Corp.)
• Original Assignee: Fuji Jukogyo KK (Subaru Corp.)
• Inventors: Maruyama, Jiro
• Granted Patent: US 7,126,451 B2
• Time in Patent Office: Days
• US Class Current: 336/232
• CPC Class Codes: H01F 27/2847 Sheets; Strips H01F27/2866 takes precedence
• CPC Class Codes: H01F 41/041 Printed circuit coils apparatus or processes for manufacturing printed circuits in general H05K3/00
• CPC Class Codes: H01F 41/074 Winding flat coils
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor

Abstract

The present invention is to provide a process for the preparation of coil for an electric appliance by which a coil for electric appliances comprising an edgewise wound square coil having small intervals between coils and high quality can be easily prepared in good productivity and low-cost. The coil for electric appliance comprising edgewise wound square coil 11 is prepared by processing mechanically an electrically conductive flat plate to form plural stripe-shaped coil fragments 1A to 1E, butting ends of the coil fragments 1A to 1E each other and welding the ends by beam to form plural one-turn square coils, each of the one-turn square coils having a ring-shape provided with a beginning end 2A and a terminal end 2B divided by a notch 3 whose location is different from one another in the one-turn square coils, and superposing the one-turn square coils on one another with shifting the locations of the notches 3 little by little in order so that the terminal and beginning ends of the one-turn square coils adjacent to each other are contact with each other to weld the terminal and beginning ends in the notch 3, whereby the one-turn square coils are spirally combined.

Claims

1. A process for the preparation of a coil for an electric appliance by squarely winding an electric conductor having a rectangular cross section such that small sides of the cross section corresponds with the direction of the coil axis of the coil to helically superpose the conductor, comprising the steps of:

processing mechanically an electrically conductive flat plate to form plural stripe-shaped coil fragments;

butting ends of the coil fragments each other and beam welding the ends to form plural one-turn square coils having notches whose locations differs from one another, each of the one-turn square coils having a ring-shape provided with a beginning end and a terminal end divided by the notch; and

superposing the one-turn square coils on one another while shifting the locations of the notches little by little in order so that the terminal and beginning ends of the one-turn square coils adjacent to each other are in contact with each other to weld or braze the terminal and beginning ends, whereby the one-turn square coils are spirally bonded.

2. A process for the preparation of a coil for an electric appliance as defined in claim 1,

the formation of the stripe-shaped coil fragments being carried out by cutting an electrically conductive flat plate in the form of a band in a desired length;

and

the formed plural one-turn square coils having the same outer size as one another.

3. A process for the preparation of a coil for electric appliance as defined in claim 1,

the formation of the stripe-shaped coil fragments being carried out by cutting plural electrically conductive flat plates having different thickness from one another to form plural stripe-shaped coil fragments having approximately the same sectional area as one another;

the formation of the plural one-turn square coils being carried out by butting ends of coil fragments having the same thickness as one another with each other and welding the ends by beam welding to form plural one-turn square coils, the one-turn square coils having an outer size different from one another and different location of the notch from one another; and

the bonding of the one-turn square coils being carried out by superposing the one-turn square coils on one another while shifting the locations of the notches little by little with increase or decrease of outer sizes of the square coils to weld or braze the terminal and beginning ends of the one-turn square coils adjacent to each other, whereby the one-turn square coils are spirally bonded.

4. A process for the preparation of a coil for electric appliance as defined in claim 3,

the formation of the plural stripe-shaped coil fragments being carried out by cutting plural electrically conductive flat plates in the form of a band in a desired length, the plural electrically conductive flat plates having thickness different from one another and approximately the same sectional area as one another.

5. A coil for an electric appliance obtained by squarely winding an electric conductor having a rectangular cross section such that small sides of the cross section correspond with the direction of the coil axis of the coil to helically superpose the conductor, comprising:

plural one-turn square coils obtained by butting ends of the stripe-shaped coil fragments made of an electrically conductive flat plate with each other in order and beam welding the ends, the plural one-turn square coils having notches whose locations differs from one another and each of the one-turn square coils having a ring-shape provided with a beginning end and a terminal end divided by the notch,

the plural one-turn square coils being superposed on one another while shifting the locations of the notches little by little so that the terminal and beginning ends of the one-turn square coils adjacent to each other are in contact with each other to weld or braze the terminal and beginning ends, whereby the one-turn square coils are spirally and continuously bonded.