Abstract: An automatic winding machine has a rotation drive mechanism, four winding core shafts protruding from the drive mechanism and being rotated integrally with a rotation center of the drive mechanism, the winding core shafts whose axial centers are parallel to the rotation center, a reciprocating mechanism for reciprocating the winding core shafts, at least one pressing roller biased in the direction of bringing close to a rotation passage of the winding core shafts from the outer circumferential side, and a conductive wire supply mechanism for continuously supplying a conductive wire between the winding core shafts and the pressing roller.

Abstract: In a manufacturing method of a coil, a plurality of unit coil portions is placed side by side in a winding axis direction, each of the unit coil portions is formed of a plurality of unit wound portions having mutually different inner circumferential lengths, and the unit wound portion having a small inner circumferential length enters inside the unit wound portion having a large inner circumferential length. In coil winding method, a step of forming an outward wound unit coil portion formed of a plurality of unit wound portions laminated from an inner circumferential side to an outer circumferential side and forming an inward wound unit coil portion formed of a plurality of unit wound portions laminated from the outer circumferential side toward the inner circumferential side are alternately repeated.

Abstract: In an electric current detector according to the present invention, an annular core 2 having a magnetic gap G and a Hall element 41 which is located in the magnetic gap of the core 2 and detects a magnitude of an electric current passing through the core 2 are arranged in an outer case 1. Here, in the core 2, a mold resin portion 3 which covers a surface of the core 2 over part of an overall length along a magnetic path thereof is molded at one or a plurality of portions along the magnetic path to configure an integral core component, the core component being fixed into the outer case 1 in a state where a surface of the mold resin portion 3 makes contact with an inner surface of the outer case 1.

Abstract: The present invention is to provide a plurality of unit coil portions formed by winding one conductive wire about a winding axis is placed side by side in the winding axis direction, each of the unit coil portions is formed by unit wound portions having different inner circumferential lengths from each other, the unit coil portion is multi-layered in at least a part thereof by pushing at least a part of the unit wound portion having a small inner circumferential length inside the unit wound portion having a large inner circumferential length, and the unit wound portion is wound along a loop shape winding route having a plurality of arc shape corner parts. In unit wound portions forming the unit coil portion, corner parts formed at the same phase angle with respect to the winding axis are formed in an arc shape having curvature center at the same position.

Abstract: An automatic winding machine has a rotation drive mechanism, four winding core shafts protruding from the drive mechanism and being rotated integrally with a rotation center of the drive mechanism, the winding core shafts whose axial centers are parallel to the rotation center, a reciprocating mechanism for reciprocating the winding core shafts, at least one pressing roller biased in the direction of bringing close to a rotation passage of the winding core shafts from the outer circumferential side, and a conductive wire supply mechanism for continuously supplying a conductive wire between the winding core shafts and the pressing roller.

Abstract: In an electric current detector according to the present invention, an annular core 2 having a magnetic gap G and a Hall element 41 which is located in the magnetic gap of the core 2 and detects a magnitude of an electric current passing through the core 2 are arranged in an outer case 1. Here, in the core 2, a mold resin portion 3 which covers a surface of the core 2 over part of an overall length along a magnetic path thereof is molded at one or a plurality of portions along the magnetic path to configure an integral core component, the core component being fixed into the outer case 1 in a state where a surface of the mold resin portion 3 makes contact with an inner surface of the outer case 1.

Abstract: A method for manufacturing a coil device comprises a first step of twisting a tip end part of the conductive wire by approximately 90 degrees with respect to a conductive wire portion arranged rearward continuously from the tip end part to form a twist part, and winding the tip end part of the conductive wire around the outer peripheral surface of the core in a lying posture on the outer peripheral surface; a second step of winding the conductive wire arranged rearward continuously from the twist part around the outer periphery surface of the core in a standing posture on the outer peripheral surface; and a third step of transforming the conductive wire on a tip end side with respect to the twist part in a direction apart from the outer periphery surface of the core to form one lead part extending substantially linearly.

Abstract: A method for manufacturing a coil device comprises a first step of twisting a tip end part of the conductive wire by approximately 90 degrees with respect to a conductive wire portion arranged rearward continuously from the tip end part to form a twist part, and winding the tip end part of the conductive wire around the outer peripheral surface of the core in a lying posture on the outer peripheral surface; a second step of winding the conductive wire arranged rearward continuously from the twist part around the outer periphery surface of the core in a standing posture on the outer peripheral surface; and a third step of transforming the conductive wire on a tip end side with respect to the twist part in a direction apart from the outer periphery surface of the core to form one lead part extending substantially linearly.

Abstract: The present invention provides an air-core coil 21 wherein one conductor is wound into a spiral form to thereby form consecutively, axially of the coil, a plurality of unit turn portions (25, 26, 27) which are different from each other in inner peripheral length and to form, axially of the coil, unit coil portions comprising the plurality of unit turn portions (25, 26, 27) to produce a partly finished coil 20, and thereafter the partly finished coil 20 is compressed to force the unit turn portion of small inner peripheral length inwardly of the unit turn portion of great inner peripheral length from among the unit turn portions providing each of the unit coil portions to thereby make each of the unit coil portions multi-layered. Thus the air-core coil 21 exhibits a smaller voltage across layers than conventionally and excellent frequency characteristics.

Abstract: The invention provides a process for fabricating a coil device which process comprises the steps of making an air-core coil 4 and fitting the air-core coil 4 around a core 1. The first step makes an air-core coil 4 comprising a plurality of unit coil portions 41, 42 arranged axially of the coil and each having one or a plurality of turns of conductor, each pair of unit coil portions adjacent to each other axially of the coil being different from each other in inner peripheral length. The fitting step fits the air-core coil 4 around the core 1 while at least partly forcing the unit coil portions 42 of small inner peripheral length inwardly of the unit coil portions 41 of great inner peripheral length by compressing the coil 4 axially thereof. The process realizes a high space factor without using a rectangular or trapezoidal conductor, and can be automated.

Abstract: The present invention provides an air-core coil 21 wherein one conductor is wound into a spiral form to thereby form consecutively, axially of the coil, a plurality of unit turn portions (25, 26, 27) which are different from each other in inner peripheral length and to form, axially of the coil, unit coil portions comprising the plurality of unit turn portions (25, 26, 27) to produce a partly finished coil 20, and thereafter the partly finished coil 20 is compressed to force the unit turn portion of small inner peripheral length inwardly of the unit turn portion of great inner peripheral length from among the unit turn portions providing each of the unit coil portions to thereby make each of the unit coil portions multi-layered. Thus the air-core coil 21 exhibits a smaller voltage across layers than conventionally and excellent frequency characteristics.

Abstract: The invention provides a process for fabricating a coil device which process comprises the steps of making an air-core coil 4 and fitting the air-core coil 4 around a core 1. The first step makes an air-core coil 4 comprising a plurality of unit coil portions 41, 42 arranged axially of the coil and each having one or a plurality of turns of conductor, each pair of unit coil portions adjacent to each other axially of the coil being different from each other in inner peripheral length. The fitting step fits the air-core coil 4 around the core 1 while at least partly forcing the unit coil portions 42 of small inner peripheral length inwardly of the unit coil portions 41 of great inner peripheral length by compressing the coil 4 axially thereof. The process realizes a high space factor without using a rectangular or trapezoidal conductor, and can be automated.

Abstract: Disclosed are a gapped magnetic core which may be coated or uncoated with an insulating layer or housed in an insulting box having a physical gap whose dimension is close to that of the gapped magnetic core and automated or semi-automated methods of applying copper wire on the gapped core or the core assembly and filling the gap with a spacer in the core or core assembly. The disclosed processes allow various combinations of core and spacer materials and gap configurations, resulting in a wide variety of core-coil assemblies which are useful as inductive components in electric and electronic circuits. Also disclosed is a core-coil assembly wherein a magnetic core with a gap directed off the conventional radial direction of a toroidally-wound core.