CN1377046A - Electromagnetic spool device and manufacturing method thereof - Google Patents

Abstract

An electromagnetic spool device wherein communication holes (15a, 15b, 15c) communicating with the innermost layer of a coil body (13) and forming passages for a uncured molding material (14) are provided respectively in the winding part (12a) of a bobbin (12), a first flange section (12b), and a second flange section (12c). Applying device of present invention, swiftly deliver a molding material to every corner of a coil body can be achieved.

Description

Electromagnetic coil device and manufacturing method thereof

technical field

The present invention relates to, for example, an electromagnetic coil device used in a motor, an electromagnetic clutch, and a manufacturing method thereof.

Background technique

In conventional electromagnetic coil devices, there is known a method of molding the coil body with a molding material such as varnish or resin in order to fix the coil body on the iron core and dissipate the Joule heat generated by the coil body to the outside. In order to securely fix the coil body, the molding material itself is required to be firm and not peel off or fall off from the iron core. In addition, in order to rapidly dissipate heat, it is effective to fill the molding material without gaps inside and outside the coil body.

Fig. 6 is an explanatory view showing, for example, a molding method of a conventional electromagnetic coil device disclosed in Japanese Patent Laid-Open No. 11-136911, showing a molding method using a casting method. After the coil body 2 is inserted into the case 1 in the casting method, the resin composition 3 is cast in the gap between the case 1 and the coil body 2 . Then, the resin composition 3 is cured by heating.

In addition, FIG. 7 is an explanatory diagram showing another molding method of a conventional electromagnetic coil device, and shows a molding method using injection molding. In the injection molding method, the case 1 into which the coil body 2 is inserted is placed in a molding machine support mold 4 . On the other hand, unhardened resin composition 3 is inserted into cylinder 6 formed in upper mold 5 .

Then, by sliding piston 7 in cylinder 6 , resin composition 3 is injected into casing 1 from injection port 8 , and the inside of casing 1 is evacuated through suction port 9 . Then, the resin composition 3 is heated and hardened by the heater 10 arranged on the supporting mold 4 of the molding machine.

In the above-mentioned conventional molding method, no matter what method is used, it is difficult to sufficiently spread the resin composition 3 between the conductors of the coil main body 2 , and there is a possibility of poor local impregnation. In particular, when the coil main body 2 with a large number of turns of hundreds or more is used, poor impregnation easily occurs in the inner layer part of the coil main body 2 and the part separated from the injection port 8 .

The object of the present invention is to solve the above-mentioned problems, thereby providing an electromagnetic coil device and a manufacturing method thereof that allow the molding material to spread to the corners of the coil body.

disclosure of invention

The electromagnetic coil device according to claim 1 of the present invention has: a bobbin having a cylindrical wrapping portion and first and second flanges provided on both ends of the wrapping portion and facing each other; a coil The main body is wound on the winding part between the first and second flange parts; the iron core has a bobbin supporting surface opposite to the second flange part, protrudes from the bobbin supporting surface and penetrates the coil The protrusion inside the mounting part and the inner wall surface opposite to the outer circumference of the coil body; and the hardened molding material filled between the bobbin and the core and between the conductors of the coil body. The innermost layer communicates with each other and serves as a communication channel for the flow path of the unhardened molding material.

In the electromagnetic coil device according to claim 2 of the present invention, the communication hole as the communication channel is provided in the first flange portion.

In the electromagnetic coil device according to claim 3 of the present invention, a molding material is filled between the wrapping portion and the protrusion, and a communication hole as a communication path is provided in the wrapping portion.

In the electromagnetic coil device according to claim 4 of the present invention, a molding material is filled between the second flange portion and the bobbin support surface, and a communication hole as a communication channel is provided in the second flange portion.

In the electromagnetic coil device according to claim 5 of the present invention, a communication groove as a communication channel is provided on a side surface of the first flange portion in contact with the coil main body.

In the electromagnetic coil device according to claim 6 of the present invention, a communication groove as a communication channel is provided on the side surface of the second flange portion in contact with the coil main body.

The electromagnetic coil device of the technical solution 7 of the present invention is that a first communication groove as a communication channel is provided on the side surface of the first flange portion in contact with the coil body, A second communication groove as a communication channel is provided on the side surface, and a connection groove for connecting the first and second communication grooves to each other is provided on the surface of the wrapping portion that contacts the coil body.

In the electromagnetic coil device according to claim 8 of the present invention, a molding material is filled between the winding portion and the protrusion, and a The groove portion extends from the end portion on the side of the first flange portion to the end portion on the side of the second flange portion.

In the electromagnetic coil device according to claim 9 of the present invention, a concave portion is provided on the inner wall surface of the iron core, and the molding material is also filled in the concave portion.

In the electromagnetic coil device according to claim 10 of the present invention, a drop-off prevention groove having a V-shaped cross section is used as the concave portion.

In the electromagnetic coil device according to claim 11 of the present invention, the plurality of detachment grooves extending in directions intersecting each other are provided on the inner wall surface when projected onto a surface parallel to the inner wall surface of the core.

The manufacturing method of the electromagnetic coil device according to the technical solution 12 of the present invention includes the following steps: placing the iron core, the bobbin installed on the iron core, and the coil body wound on the bobbin in the vacuum chamber; Vacuum the vacuum tank and inject unhardened molding material from the innermost layer of the coil body through the connecting channel provided on the winding frame, and fill the gap between the winding frame and the core and the conductors of the coil body. A step of hardening the molding material; and a step of hardening the unhardened molding material.

The manufacturing method of the electromagnetic coil device according to the thirteenth aspect of the present invention is to use a cylindrical wrapping part having a coil body wound thereon, to be provided on one end of the wrapping part, and to have a coil communicating with the innermost layer of the coil body. The first flange part of the communication hole as the communication channel and the bobbin of the second flange part provided on the other end of the package part and opposite to the first flange part are injected into the unhardened modeling material.

A brief description of the drawings

Fig. 1 is a perspective view showing an electromagnetic coil device according to Embodiment 1 of the present invention.

Fig. 2 is a sectional view along line II-II in Fig. 1 .

Fig. 3 is an enlarged perspective view showing a main part of Fig. 1 .

Fig. 4 is an explanatory view showing a state in the middle of manufacturing the electromagnetic coil device of Fig. 1 .

Fig. 5 is a sectional view of an electromagnetic coil device according to Embodiment 2 of the present invention.

Fig. 6 is an explanatory view showing an example of a conventional method of molding an electromagnetic coil device.

Fig. 7 is an explanatory view showing another example of a conventional method of molding an electromagnetic coil device.

Embodiment of the invention

Next, embodiments of the present invention will be described with reference to the drawings.

Embodiment 1

Fig. 1 is a perspective view showing an electromagnetic coil device according to Embodiment 1 of the present invention, Fig. 2 is a cross-sectional view along line II-II in Fig. 1, Fig. 3 is a perspective view showing an enlarged main part of Fig. 1 , in this example, Indicates the motor used for the hoist of the elevator.

In the figure, the electromagnetic coil device has an iron core 11, a bobbin 12 installed on the iron core 11, a coil body 13 wound on the bobbin 12, and a coil body filled between the bobbin 12 and the iron core 11. The molding material 14 that is hardened between the conductors (such as enameled wire) of 13.

The bobbin 12 has a cylindrical winding portion 12a, and first and second flange portions 12b, 12c provided on both ends of the winding portion 12a and facing each other. The coil main body 13 is wound around the winding part 12a between the first and second flange parts 12b and 12c.

The iron core 11 has a bobbin supporting surface 11a facing the second flange portion 12c, a rectangular parallelepiped protruding portion 11b protruding from the bobbin supporting surface 11a and penetratingly inserted into the inside of the winding portion 12a, and the outer periphery of the coil body 13. A pair of inner wall surfaces 11c, 11d facing each other and parallel to each other.

As the molding material 14, for example, heat-curable epoxy resin or the like is used. Moreover, the molding material 14 is also filled between the winding part 12a and the protrusion part 11b, and between the 2nd flange part 12c and the bobbin support surface 11a.

The wrapping portion 12a, the first flange portion 12b, and the second flange portion 12c are respectively provided with communication holes 15a to 15c serving as communication channels communicating with the innermost layer of the coil body 13 . The communication spaces 15a to 15c serve as flow paths for the molding material 14 that is not hardened (before hardening), respectively.

On the inner surface of the wrapping portion 12a opposite to the side surface of the protrusion 11b, there is formed a yoke extending from the end portion on the side of the first flange portion 12b to the end portion on the side of the second flange portion 12c at right angles to the bobbin supporting surface 11a. The cross section extending in the direction is a V-shaped groove portion (notch) 16 . On the inner wall surfaces 11c and 11d of the iron core 11, a detent groove 17 having a V-shaped cross section as a recess is provided. The molding material 14 is also filled in the detachment groove 17 .

FIG. 4 is an explanatory view showing a state in the middle of manufacturing the electromagnetic coil device of FIG. 1 . In the figure, an exhaust pipe 22 is connected to the vacuum tank 21 . An exhaust valve 23 is provided on the exhaust pipe 22 . An injection pipe 24 is inserted into the vacuum chamber 21 . The front end portion of the injection pipe 24 is connected to the communication hole 15 b of the bobbin 12 . An injection valve 25 is provided on the injection pipe 24 . An injection device 26 for injecting the uncured molding material 14 into the communication hole 15b is connected to the base end portion of the injection pipe 24 .

Next, a method of manufacturing the electromagnetic coil device will be described. First, the coil main body 13 with a predetermined number of turns is wound on the bobbin 12 by a winding machine (not shown). Then, the bobbin 12 is detached from the winding machine and mounted on a predetermined position of the iron core 11 . Next, the iron core 11 is placed in the vacuum chamber 21. At this time, the side surfaces without the iron core 11 of the inner wall surfaces 11c and 11d abut against a flat clamp or the like to prevent the uncured molding material 14 from flowing out.

Then, the inside of the vacuum chamber 21 is evacuated by a vacuum pump (not shown) through the exhaust pipe 22 . When the inside of the vacuum chamber 21 reaches a predetermined degree of vacuum, the exhaust valve 23 is closed to maintain the degree of vacuum. In this state, the injection valve 25 is opened, and the unhardened molding material 14 is injected into the communication hole 15 b through the injection tube 24 . The necessary injection amount of the molding material 14 is obtained in advance by calculation.

After the molding material 14 is injected, the molding material 14 is heated and hardened in a heating furnace (not shown). At this time, when the temperature is raised to the curing temperature of the molding material 14 at once, since the resin constituting the molding material 14 shrinks due to curing, peeling and cracks may occur between the iron core 11, so it is preferable to raise the temperature in two stages.

In addition, the reliability can be improved by vacuum degassing the molding material 14 before injection to remove air bubbles in the molding material 14 . In addition, in order to improve the fluidity and impregnation properties of the molding material 14, it is also effective to heat the molding material 14 and the iron core 11 in advance. At this time, current may be passed through the coil main body 13 to heat itself.

Here, when manufacturing an electromagnetic coil device with 800 turns, the pressure in the vacuum chamber 21 is set to 1.33322×10 ² Pa (1 Torr), and the molding material 14 is injected at a preheating temperature of about 80°C. It was confirmed that the molding material 14 was filled inside and outside the coil main body 13 without gaps.

In this electromagnetic coil device, since the communication holes 15a, 15b, 15c communicated with the innermost layer of the coil body 13 are provided on the bobbin 12, the molding material 14 can be spread to the corners of the coil body 13, The coil body 13 can be firmly fixed on the iron core 11, and the heat generated by the coil body 13 can be released rapidly.

In addition, since the communication hole 15b is provided in the first flange portion 12b, and the unhardened molding material 14 is injected through the communication hole 15b, the molding material 14 can be filled in the entire coil body 13 more reliably with a simple structure. In addition, since the winding portion 12a and the second flange portion 12c are also provided with the communicating holes 15a, 15c, the molding material 14 can be more reliably filled in the entire coil body 13 with a simple structure.

Furthermore, since the groove portion 16 is formed on the inner surface of the roll portion 12a, the molding material 14 can be more reliably filled between the roll portion 12a and the protrusion portion 11b. In addition, by providing the communication holes 15a, 15b, 15c and the groove 16 on the bobbin 12, the impregnation speed of the unhardened molding material 14 can be accelerated, and the working time can be shortened.

In addition, since the anti-off groove 17 is provided on the inner wall surface 11c of the iron core, the anti-off groove 17 is also filled with the molding material 14, so the molding material 14 can be more reliably prevented from coming off the iron core 11, and the coil body 13 can be firmly fixed. fixed on the core 11. In addition, since the movement of the molding material 14 can be suppressed, long-term electromagnetic vibration can be withstood, and the reliability can be improved.

In Embodiment 1, the slip-off preventing groove 17 having a V-shaped cross section is shown as a concave portion, but the cross-sectional shape of the slip-off preventing groove 17 may also be U-shaped, etc., and various changes may be made according to the workability and the effect of preventing slip-off, etc. .

In addition, instead of the slip-off preventing groove 17, one or more independent dimples may be provided as recesses on the inner wall surfaces 11c and 11d.

In addition, in Embodiment 1, each of the inner wall surfaces 11c and 11d is provided with mutually parallel linear anti-fall grooves 17, but it is also possible to project a plurality of anti-escape grooves extending in directions intersecting each other. In the case of a surface parallel to the inner wall surfaces 11c, 11d, it is provided on the inner wall surfaces 11c, 11d. At this time, the molding material 14 can be more reliably prevented from coming off from the iron core 11 for all directions. In addition, a curved anti-off groove can also be provided.

In addition, in Embodiment 1, the groove portion 16 is provided on the inner surface of the package portion 12a, but it may also be provided on the side surface of the protrusion portion 11b, or provided on the inner surface of the package portion 12a and the side surface of the protrusion portion 11b. Therefore, the molding material 14 can be more reliably filled between the roll portion 12a and the protruding portion 11b.

Implementation form 2

Fig. 5 is a cross-sectional view of an electromagnetic coil device according to the second embodiment. In the drawing, the bobbin 31 has a cylindrical winding portion 31a, and first and second flange portions 31b, 31c provided on both ends of the winding portion 31a and facing each other.

On the side surface of the first flange portion 31b in contact with the coil body 13, a first communication groove 32a as a communication channel is provided, and on the side surface of the second flange portion 31c in contact with the coil body 13, a first communication groove 32a is provided as a communication channel. The second communication groove 32b of the channel. A connection groove 33 that connects the first and second communication grooves 32a, 32b to each other is provided on the surface of the wrapping portion 31a that is in contact with the coil main body 13 . Other structures are the same as those in Embodiment 1.

In this electromagnetic coil device, since the first and second communication grooves 32a, 32b and the connection groove 33 communicated with the innermost layer of the coil body 13 become the flow path of the unhardened molding material 14, the molding material 14 can be Throughout the corners of the coil body 13, the coil body 13 can be firmly fixed on the iron core 11, and the heat generated by the coil body 13 can be released quickly.

As mentioned above, in the electromagnetic coil device according to the technical solution 1 of the present invention, since the communication passage which communicates with the innermost layer of the coil body and becomes the flow path of the unhardened molding material is provided on the bobbin, the molding material can be spread throughout. to the corner of the coil body.

In the electromagnetic coil device according to claim 2 of the present invention, since the communication hole is provided in the first flange portion, the molding material can be more reliably filled in the entire coil body with a simple structure.

In the electromagnetic coil device according to claim 3 of the present invention, since the communicating hole is provided in the winding portion, the molding material can be more reliably filled in the entire coil body with a simple structure.

In the electromagnetic coil device according to claim 4 of the present invention, since the communication hole is provided in the second flange portion, the molding material can be more reliably filled in the entire coil body with a simple structure.

In the electromagnetic coil device according to the fifth aspect of the present invention, since a communication groove as a communication channel is provided on the side surface of the first flange portion in contact with the coil body, the molding material can be spread to the corners of the coil body.

In the electromagnetic coil device according to the sixth aspect of the present invention, since the communication groove as the communication channel is provided on the side contacting with the coil body of the second flange portion, the molding material can be spread to the corners of the coil body.

In the electromagnetic coil device according to the seventh aspect of the present invention, since the first communication groove as a communication channel is provided on the side surface of the first flange part that is in contact with the coil body, the side surface of the second flange part that is in contact with the coil body The second communication groove as a communication channel is provided on the top, and the connection groove connecting the first and second communication grooves is provided on the surface of the winding part that is in contact with the coil body, so the molding material can be spread throughout the coil body more reliably. at the corner.

In the electromagnetic coil device according to claim 8 of the present invention, since at least one of the side surface of the protruding part and the inner surface of the package part opposite to the side surface is formed with a Since the groove portion extends from the end portion on the side of the flange portion, the molding material can be more reliably filled between the roll portion and the protrusion portion.

In the electromagnetic coil device of technical solution 9 of the present invention, since a recess is provided on the inner wall of the iron core, and the molding material is filled in the recess, it can more reliably prevent the molding material from coming out of the iron core, and the coil body can be firmly fixed on the iron core. superior.

In the electromagnetic coil device according to claim 10 of the present invention, since the detachment preventing groove having a V-shaped cross section is used as the recess, the molding material can be more reliably prevented from detaching from the iron core with a simple structure.

In the electromagnetic coil device according to claim 11 of the present invention, since the plurality of detachment grooves extending in directions intersecting with each other are provided on the inner wall surface when projected onto a surface parallel to the inner wall surface of the iron core, it is possible to change the electromagnetic coil device in all directions. The molding material is reliably prevented from falling out of the core.

In the manufacturing method of the electromagnetic coil device according to the technical solution 12 of the present invention, the unhardened molding material is injected from the innermost side of the coil body through the communication channel provided on the winding frame, so the molding material can be spread to the corners of the coil body place.

In the manufacturing method of the electromagnetic coil device according to the thirteenth aspect of the present invention, since the unhardened molding material is injected from the communicating hole provided on the first flange portion, the molding material can spread to the corners of the coil body.

Claims (13)

1. An electromagnetic coil device, characterized in that it has: A bobbin frame having a cylindrical winding portion and first and second flange portions provided on both ends of the winding portion and facing each other; a coil body wound on the winding portion between the first and second flange portions; The iron core has a bobbin supporting surface facing the second flange portion, a protrusion protruding from the bobbin supporting surface and penetratingly inserted inside the winding portion, and an outer peripheral portion facing the coil body. the inner wall of the Filling the hardened molding material between the bobbin and the core and between the conductors of the coil body, The bobbin is provided with a communication channel which communicates with the innermost layer of the coil body and serves as a flow path of the unhardened molding material. 2. The electromagnetic coil device according to claim 1, wherein a communication hole as a communication channel is provided in the first flange portion. 3. The electromagnetic coil device according to claim 1 or 2, wherein a molding material is filled between the wrapping portion and the protruding portion, and a communication hole as a communication channel is provided in the wrapping portion. 4. The electromagnetic coil device according to claim 1 or 2, wherein a molding material is filled between the second flange portion and the bobbin supporting surface, and a molding material is provided on the second flange portion as The connecting hole of the connecting channel. 5. The electromagnetic coil device according to claim 1 or 2, wherein a communication groove as a communication channel is provided on a side surface of the first flange part in contact with the coil main body. 6. The electromagnetic coil device according to claim 1 or 2, wherein a communication groove as a communication channel is provided on a side surface of the second flange portion that is in contact with the coil main body. 7. The electromagnetic coil device according to claim 1 or 2, characterized in that, on the side surface of the first flange part in contact with the coil body, a first communication groove as a communication channel is provided, and on the second flange part A second communication groove as a communication channel is provided on the side of the winding part that is in contact with the coil body, and a connecting groove that connects the first and second communication grooves to each other is provided on the surface of the wrapping part that contacts the coil body. 8. The electromagnetic coil device according to claim 1 or 2, wherein a molding material is filled between the winding portion and the protruding portion, and the side surface of the protruding portion and the winding portion opposite to the side face are filled with a molding material. A groove extending from the end on the first flange side to the end on the second flange side is formed on at least one of the inner surfaces of the portion. 9. The electromagnetic coil device according to claim 1 or 2, wherein a concave portion is provided on an inner wall surface of the core, and the molding material is also filled in the concave portion. 10 . The electromagnetic coil device according to claim 9 , wherein the concave portion is a V-shaped anti-slip groove in cross section. 11 . 11. The electromagnetic coil device according to claim 10, characterized in that, on the inner wall surface of the iron core, there are provided a plurality of stoppers extending in directions intersecting each other when projected onto a surface parallel to the inner wall surface of the iron core. groove. 12. A method for manufacturing an electromagnetic coil device, comprising the following steps: The process of placing the iron core, the winding frame installed on the iron core, and the coil body wound on the winding frame in the vacuum chamber; Vacuum the inside of the vacuum chamber and inject unhardened molding material from the innermost layer of the coil body through the communication channel provided on the winding frame, and inject the unhardened molding material between the winding frame and the iron core The process of filling the unhardened molding material between the conductors of the coil body and the coil body; and A step of hardening the unhardened molding material. 13. The manufacturing method of the electromagnetic coil device according to claim 12, wherein the bobbin has: a cylindrical wrapping portion wound with the coil body; There is a first flange part communicating with the innermost layer of the coil body as a communication hole of the communication channel; and a second flange part provided on the other end of the package part and opposite to the first flange part, The communicating hole is filled with unhardened molding material.

Images