JP2008312353A - Serpentine annular coil and manufacturing method thereof - Google Patents

Abstract

[PROBLEMS] To achieve sufficient insulation even if the space between the iron core and the meandering coil is made smaller to make it compact, and it is excellent in insulation that can greatly reduce the number of parts. A meandering annular coil is obtained.
A synthetic resin outer package is integrally attached to an outer periphery of a meandering annular coil molded body so as to wrap the meandering annular coil molded body along the shape of the meandering annular coil molded body. The meandering annular coil 1 is obtained by covering the outer periphery of the annular winding coil 2 with the exterior body 6 and then performing meandering bending, or forming the meandering winding coil 2 by meandering bending. The body 5 is obtained, and the outer periphery of the meandering annular coil molded body 5 is covered with the exterior body 6.
[Selection] Figure 1

Description

  The present invention relates to a meandering annular coil used for a stator of an electric motor and a manufacturing method thereof.

Conventionally, for example, a permanent magnet type AC motor mounted on a hybrid vehicle as a vehicle drive source together with an internal combustion engine has been proposed in which the coil constituting the stator of the motor is a meandering annular coil for the purpose of reducing the number of parts. (See Patent Documents 1 and 2). The meandering annular coil is integrally formed with a plurality of meandering portions so as to protrude at a predetermined pitch in the circumferential direction and at a predetermined depth (height) in the axial direction. It was possible to reduce the number of stator parts and greatly improve the assemblability while eliminating the need to distribute power to each bobbin by applying a winding core to each. Furthermore, while improving the winding space factor in the stator, the coil end height was reduced and the motor axial dimension was reduced, and a motor with improved loadability on a vehicle or the like could be obtained. Is.
JP 2006-280188 A JP 2006-280189 A

However, since the above-described meandering annular coil is formed by meandering bending of the annular winding coil, it is difficult to form it into a complete cylindrical shape. Occurred.
(1) In order to ensure insulation between the iron core and the meandering annular coil, a large gap as an air layer for insulation purposes must be provided between the iron core and the meandering annular coil. ing. Further, in the case of a stator employing a conventional meandering annular coil, as shown in FIG. 9, a U-phase toothing ring 51, a V-phase toothing ring 52, a W-phase toothing ring 53, a U-phase meandering annular coil 54, and a W-phase inside the stator. In order to prevent a short circuit between the phase meandering annular coils 55, a large number (40 in the case of the figure) of insulators 56 are required as a short circuit prevention component.
(2) Further, at the time of assembly, there is a concern about scratches due to rubbing with the iron core, and depending on the degree, it becomes a fatal problem, so it is necessary to improve the scratch resistance.

  Therefore, the present invention can sufficiently ensure the insulation even if the gap is made smaller by making the gap with the iron core at the time of assembly of the meandering annular coil, and the number of parts can be greatly reduced, It is another object of the present invention to provide a serpentine annular coil having excellent insulating properties that can be incorporated without breaking the insulation of the serpentine annular coil even when it is rubbed against an iron core or the like during assembly, and a method for manufacturing the same.

  The meandering annular coil of the present invention that solves the above problems is a meandering annular coil having a plurality of meandering portions protruding in the axial direction, and is formed so as to have a plurality of meandering portions protruding in the axial direction from the annular winding coil. A synthetic resin exterior body is integrally attached to the outer periphery of the meandering annular coil molded body so as to wrap the meandering annular coil molded body along the shape of the serpentine annular coil molded body. Is. The meandering annular coil molded body can be formed by integrally forming an annular winding coil formed by winding a coated wire having an insulating film formed on the outer periphery of a rectangular wire in an annular manner, preferably by meandering bending. . And it is desirable for the said exterior body to be formed with resin with heat resistance more than the heat-resistant temperature of the said covered wire.

  In the meantime, the manufacturing method of the meandering annular coil according to the present invention integrally attaches the outer casing made of synthetic resin along the meandering annular shape to the outer periphery of the meandering annular coil having a plurality of meandering portions protruding in the axial direction. A meandering annular coil manufacturing method comprising: mounting a synthetic resin outer package around an outer periphery of the annular winding coil so as to wrap the annular winding coil; and mounting the synthetic resin outer package The annular winding coil is formed into a meandering annular coil by meandering bending. In another method of manufacturing the serpentine annular coil of the present invention, a synthetic resin exterior body is integrally formed on the outer periphery of the serpentine annular coil having a plurality of meandering portions protruding in the axial direction along the serpentine annular shape. A meandering annular coil formed body is formed by meandering and forming an annular winding coil in a meandering manner, and forming the meandering annular coil shaped body. A synthetic resin exterior body is integrally mounted along the shape of the outer periphery.

  As described above, the meandering annular coil of the present invention is a method of forming an annular winding coil after mounting an exterior body on the annular winding coil, or forming the annular winding coil into a meandering annular coil molded body, A method of mounting the outer package can be manufactured by any method, but in any of the methods, the outer package has a recess in which the annular winding coil or the meandering annular coil molded body is fitted by a plastic sheet. A body body is formed, and an annular winding coil or a meandering annular coil molded body is fitted in a recess of the exterior body body, and the opening is covered with a lid body made of a plastic sheet, and the lid body and the exterior body body It is possible to employ a means for adhering together. As another method, the exterior body main body may be formed by directly molding a plastic sheet along the outer periphery of the annular winding coil or the meandering annular coil molded body. Furthermore, as another method, the exterior body can be molded using a mold having a recess into which the annular winding coil or the meandering annular coil molded body is fitted.

  Further, particularly when the exterior body is mounted on the meandering annular coil molded body, the exterior body is fitted with a lower exterior body in which the lower half of the serpentine annular coil molded body is fitted and an upper half of the serpentine annular coil molded body. The upper exterior body to be joined is molded with a synthetic resin, and the lower exterior body and the upper exterior body are fitted to the meandering annular coil molded body from above and below, and the edge abutting portion between the lower exterior body and the upper exterior body It is also possible to adopt a technical means of bonding the two together. As a molding method of the exterior body, vacuum molding, pressure molding, or combined molding of vacuum pressure and air is desirable.

  According to the inventions of the first to ninth aspects, it is possible to obtain a meandering annular coil excellent in insulation that can be incorporated without breaking the insulation of the meandering annular coil even if it is rubbed with an iron core or the like at the time of incorporation. Even if the gap with the iron core or the like when assembling the meandering annular coil is made smaller, sufficient insulation can be ensured, so that a companion stator can be obtained, and the number of parts of the stator is reduced from the conventional one. Compared to this, it can be greatly reduced.

  According to the second aspect of the present invention, since the outer peripheral portion of the strand is further covered with the insulating film, the insulation between the coil wires is broken even if a severe forming load of meandering bending is applied. Without being able to maintain a high degree of insulation. Further, according to the invention of claim 3, it can be adapted to the use environment (heat resistance, durability, etc.) of an automobile engine or the like.

  According to the invention described in claim 7, since the exterior body is directly molded and attached to the annular winding coil or the meandering annular coil by vacuum forming, pressure forming, or vacuum / pressure combined use molding, Equipment costs can be reduced without the need for special molds. Further, according to the inventions of claims 8 and 9, since the exterior body is molded using a mold, the mounting body can be previously molded separately from the meandering annular coil production line, and the productivity is increased. In addition, the material of the molding resin is not necessarily limited to a resin that can be vacuum-molded, and the selection range of the heat-resistant resin material can be expanded.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings.
The meandering annular coil of the present embodiment is a coil suitable for a U-phase or W-phase coil of a stator such as a three-phase synchronous motor or a DC brushless motor mounted on a hybrid vehicle as a vehicle drive source together with an internal combustion engine. FIG. 1 is a perspective view of a meandering annular coil according to the present embodiment of the present invention, and shows a state in which the exterior body 6 is peeled off leaving a part. As shown in FIG. 3, the meandering annular coil 1 of the present embodiment is formed by winding five rows and two stages of a covered wire 13 in which an insulating coating layer 11 is formed on the outer periphery of a pure copper-based flat wire 10. Made of an electrically insulating synthetic resin along the shape of the meandering annular coil molded body on the outer periphery of the meandering annular coil molded body 5 having a plurality of meandering portions 3 (10 in this embodiment) projecting in the axial direction. The exterior body 6 is integrally mounted. As shown in FIG. 2, it is desirable that the outer package 6 covers the lead wires 7 and 8 as well.

As a resin of the outer package 6, as a condition when the motor incorporating the meandering annular coil is used in an automobile, it is naturally insulative. Has durability, has a durability of more than a certain number of years (HG indication), has excellent adhesion to the meandering annular coil molded body, and can be used even if the oil for oil cooling contains moisture Thus, it is desirable that oil resistance and water deterioration resistance are excellent, and that moldability (vacuum forming or pressure forming or combined use of vacuum and pressure forming is possible) is excellent.
As resins that satisfy all or part of these conditions and can be used, polypropylene (PP), fluororesins perfluoroalkoxy (PFA) and polytetrafluoroethylene (PTFE), olefin resins, polyethylene terephthalate (PET) , C-PET), 11,12 nylon, polyphenylene sulfide resin (PPS), polyamide (PA), polyethersulfone (PESF), polyetherimide (PEI), polyimide (PI), polybutylene terephthalate (PBT), polyethylene And naphthalate (PEN).

Next, an embodiment of the method for manufacturing the meandering annular coil will be described with reference to the drawings.
As shown in FIG. 2, the meandering annular coil 1 of this embodiment is covered with an outer package 6 so as to wrap around the outer peripheral portion of the annular winding coil 2, and is meandered by meandering bending from the outer sheath-coated annular winding coil 4. A method for obtaining the annular coil 1 and an annular winding coil 2 are meandered and bent to obtain a meandering annular coil molded body 5, and the outer peripheral portion of the meandering annular coil molded body 5 is covered with an exterior body 6. There are two ways to obtain the coil 1.

  As shown in FIG. 3, the annular winding coil 2 employs a pure copper-based rectangular wire as the element wire 10 or a surface of which is subjected to surface treatment such as nickel plating, and an insulating coating layer 11 is provided on the outer peripheral portion thereof. Forming. In the present embodiment, the adhesive layer 12 is further formed on the outer peripheral portion of the insulating coating layer 11. However, the adhesive layer 12 is not necessarily provided when the outer winding body is directly attached to the annular winding coil and the meandering annular coil is formed. There is no need. The insulating coating layer 11 is not particularly limited as long as it is a polyamide-imide resin, a fluorine resin, or other resin having heat resistance, wear resistance, and durability. The insulating coating layer is preferably thick so that the insulating performance is not destroyed by pinholes or wrinkles during molding / incorporation. The insulation coating layer can be formed by multiple coatings of molten resin, but as a film formation method that ensures uniformity, continuous molding is performed so that the outer periphery is covered by extrusion molding of the insulation resin to the strand 10 Is preferred.

  As the adhesive layer 12, a general adhesive resin can be employed, and for example, an epoxy resin, a phenol resin, a urethane resin, a melamine resin, a urea resin, an unsaturated polyester resin, and the like can be employed. In order to prevent adhesion to the mold during molding, the adhesive layer is dried after being applied to the strands, and after molding, it is polymerized and solidified by heating and heat treatment, and the adhesive layers of adjacent wires are melt bonded together It is preferable that they are integrated. The thickness of the adhesive layer only needs to be able to adhere to each other to such an extent that the insulated wires after the coil molding are not scattered.

  As described above, the covered wire 13 having a cross-sectional structure made of copper / insulating coating / adhesive layer is obtained from the central portion, and the annular winding coil 2 as shown in FIG. The annular winding coil 2 of the present embodiment has both ends projecting outward to form lead wires 7 and 8, and the cross section is formed in 5 turns and 2 steps as shown in FIG. However, it is not necessarily limited thereto, and is appropriately selected according to the rating of the motor. An embodiment in which the outer package is mounted on the outer peripheral portion of the annular winding coil formed as described above will be described with reference to FIG.

FIG. 4 is a cross-sectional view of the annular winding coil in the order of steps in which an exterior body is mounted on the outer periphery of the annular winding coil.
As shown in FIG. 4A, the annular winding coil 2 is set in a vacuum box 15 that can be vacuum-sucked from the bottom, and a plastic sheet 16 heated so as to be vacuum-formed is placed on the upper surface of the annular winding coil. Then, by vacuum suction from the bottom of the suction box 15, the plastic sheet 16 comes into close contact with the outer, inner, and upper three circumferential portions of the annular winding coil as shown in FIG. The exterior body 19 having a recess having a height in which the wire coil is buried is formed. In this state, the outer body main body is taken out of the vacuum box integrally with the annular winding coil, and a plastic sheet 17 serving as a lid is covered with the opening of the outer body main body 19 as shown in FIG. The outer periphery of the annular winding coil is completely encased in a plastic sheet by heat-sealing to the flange portion of the exterior body 19 that is flush with the opening by the mold 18. Then, by trimming the portion protruding from the annular winding coil wrapping portion ((d) in the same figure), the entire coated annular winding coil 4 whose outer peripheral portion is completely covered with the exterior body 6 made of a plastic sheet is obtained. ((E) in the figure).

  Next, the whole coated annular winding coil 4 is meandered and bent by a molding press composed of a meandering annular coil forming apparatus to obtain a meandering annular coil 1 having a meandering portion 3 as shown in FIG. As shown in FIG. 3C, the meandering annular coil 1 obtained as described above is in a state in which the exterior body 6 is in close contact and uniformly covered with the entire outer peripheral portion. Since it is excellent in insulation and does not conduct electrically even if it is in contact with each other, it is not necessary to provide a space for securing insulation between the coils and the iron core or casing, and can be closely integrated. . Accordingly, the stator can be formed compactly. In addition, since the meandering annular coil 1 is thickly covered with an exterior body, even if the exterior body surface is damaged during normal installation, there is no risk of the insulation being destroyed. As shown in FIG. 8, the stator of the three-phase synchronous motor has a U-phase stator ring 20, a U-phase serpentine annular coil 21 formed of the serpentine annular coil of the present embodiment, a V-phase stator ring 22, It is possible to assemble the five components of the W-phase serpentine ring coil 23 and the W-phase stator ring 24 formed by the serpentine ring coil of the embodiment in a direct contact state. Therefore, as shown in FIG. 9, the stator of a conventional three-phase synchronous motor using the same type of meandering annular coil can be greatly reduced in the number of parts.

  In the above embodiment, the outer body is formed by vacuum forming a plastic film directly on the annular winding coil, but as shown in FIG. 5, a vacuum forming die 30 having the same shape as the annular winding coil is prepared, The exterior body main body 19 is previously vacuum-formed by the same method as described above using the vacuum forming die (FIG. 5A), and an annular winding coil is attached to the die-cut exterior body body (FIG. 5B). The cover body film may be heat-sealed by the same method as described above (figure (c)), and the exterior body may be formed.

In addition, since the exterior body may be formed by a pressure difference between the inside and the outside of the sheet, the exterior body is not necessarily formed by vacuum forming, but can be formed by pressure forming using a forming die instead of vacuum forming. In order to shorten the molding time and improve the shape accuracy, it is more preferable that the molding is a combination of vacuum molding and pressure molding.
Furthermore, the exterior body is not necessarily limited to the case where the exterior body is composed of a lid body. For example, in the case of the annular winding coil of the above-described embodiment, a lower exterior body that covers the first stage winding, The exterior body may be formed by separately molding the upper exterior body that covers the windings of the eyes and heat-sealing the portions that are in contact with each other with the annular winding coil sandwiched from above and below. Further, in each of the embodiments described above, the bonding is performed by heat fusion, but it is not necessarily limited to heat fusion, and it is also possible to bond using an adhesive. Furthermore, the form of the exterior body is not limited to the form shown in FIGS. 4 and 5, and may be the form shown in FIGS. 6A and 6B, for example. 6A, the exterior body main body 25 has a bent piece 26 that bends on the upper surface of the annular winding coil 2, and a lid body 27 is provided on the upper surface thereof. Glued. 6B, the exterior body main body 19 has the same shape as that of the embodiment shown in FIG. It has a bent piece 31 that bends, and is also bonded to the side wall surface of the exterior body.

  In the above embodiment, the outer winding body is attached to the annular winding coil, and then the meandering annular coil is subjected to meandering bending. In order to avoid this, it is desirable to attach the outer package after the meandering bending process. When the exterior body is mounted on the serpentine annular coil molded body, the plastic sheet is directly adhered to the serpentine annular coil molded body itself and mounted by vacuum molding, pressure molding, or vacuum / compression combined molding, as in the above embodiment. be able to. Alternatively, it can be formed by forming an exterior body body with a molding die, covering the opening with a plastic sheet serving as a lid body in a state in which the meandering annular coil molded body is fitted to the exterior body body.

FIG. 7 shows an embodiment in which an exterior body is mounted on a meandering annular coil molded body.
In the present embodiment, first, the lower exterior body 35 that covers the first stage winding of the meandering annular coil and the upper exterior body 36 that covers the second stage winding are separately molded by a mold, and the lower side The exterior body 35 and the upper exterior body 36 are respectively covered with the meandering annular coil molded body 5 from the lower side and the upper side, and the joint surfaces thereof are bonded and integrated. As an apparatus for that purpose, for example, the lower exterior body 35 is fitted into the lower joining tool in which the fitting recess along the form is formed so that the lower exterior body 35 is fitted, and the upper exterior body 36 is fitted. In this way, the upper exterior body 36 is mounted and held on the upper joining tool in which the fitting concave portion along the form is formed, and the meandering annular coil molded body is sandwiched from the upper and lower sides, and is pressed and held in that state. The contact surfaces of the side exterior body 35 and the upper exterior body 36 are adhered to each other. Moreover, an exterior body may be shape | molded so that the junction part of the lower exterior body 35 and the upper exterior body 36 may overlap, and an overlap part may be adhere | attached.

  The method for forming a meandering annular coil and the meandering annular coil of the present invention can be particularly suitably used as a stator winding of a motor for a hybrid vehicle or a motor for an electric vehicle, but is not limited thereto, and is used for an insulating coat of a general stator coil. Is possible.

It is a perspective view of the meandering annular coil which concerns on embodiment of this invention. It is a conceptual diagram which shows the outline of the manufacturing method of the meandering annular coil which concerns on embodiment of this invention. It is sectional drawing which shows the covered wire which forms the meandering annular coil of this invention, (A) is sectional drawing of a covered wire single wire. (B) is sectional drawing which shows the cross section (II-II cross section of FIG. 2) before the cross-section (II cross section of FIG. 2) of an annular winding coil or the exterior body mounting process of a meandering annular coil. (C) shows a cross section after the outer body mounting process of the annular winding coil (III-III cross section of FIG. 2) or a cross section after the outer body mounting process of the meandering annular coil molded body (IV-IV cross section of FIG. 2). It is sectional drawing. (A)-(e) is process drawing which shows the process of mounting | wearing an annular winding coil molded object by vacuum forming based on embodiment of this invention. (A)-(c) is process drawing which shows to the middle of the process of mounting | wearing the annular winding coil molded object which concerns on other embodiment of this invention with the exterior body vacuum-formed using the shaping | molding die. (A), (b) has each shown the covering form by the exterior body of the annular winding coil or meandering annular coil molded object which concerns on other embodiment of this invention. In the manufacturing method of the meandering annular coil which concerns on other embodiment of this invention, it is a schematic diagram in the case of coat | covering a meandering annular coil molded object with a lower exterior body and an upper exterior body. It is an expanded view at the time of assembling a stator by applying the meandering annular coil which concerns on embodiment of this invention. It is an expanded view at the time of assembling a stator by applying the conventional meandering annular coil.

Explanation of symbols

1 Meandering Ring Coil 2 Ring Winding Coil 3 Meandering Part
4, 4-1, 4-2, outer cover-covered annular winding coil 5 meandering annular coil molded body 6 outer cover 7, 8 lead wire 10 element wire 11 insulating cover layer 12 adhesive layer 13 cover wire 15 suction box 16, 17 plastic Sheet 18 Heat seal type 19, 25 Exterior body 20 U-phase stator ring 21 U-phase serpentine annular coil 22 V-phase stator ring 23 W-phase serpentine annular coil 24 W-phase stator ring 26, 31 Bending pieces 27, 29 Lid 30 Mold 35 Lower exterior body
36 Upper exterior body 51 U-phase tooth sling 52 V-phase tooth sling 53 W-phase tooth sling 54 U-phase serpentine annular coil 55 W-phase serpentine annular coil 56 Insulator

Claims (9)

  A meandering annular coil having a plurality of meandering portions protruding in the axial direction, the outer peripheral portion of the meandering annular coil molded body having a plurality of meandering portions protruding in the axial direction from the annular winding coil, A serpentine annular coil comprising a synthetic resin outer body integrally mounted so as to wrap around a serpentine annular coil molded body along the shape of the serpentine annular coil molded body.   2. The meandering annular coil according to claim 1, wherein the meandering annular coil molding is formed from an annular winding coil made of a coated wire in which an insulating film is formed on an outer peripheral portion of a flat wire.   The meandering annular coil according to claim 2, wherein the outer package is formed of a resin having a heat resistance equal to or higher than a heat resistance temperature of the coated wire.   A method for producing a serpentine annular coil comprising integrally mounting a synthetic resin outer body along the meandering annular shape on the outer periphery of a serpentine annular coil having a plurality of meandering portions protruding in the axial direction, A sheathing made of synthetic resin is attached to the outer periphery of the annular winding coil so as to wrap the annular winding coil, and the annular winding coil with the sheathing made of synthetic resin is meandered by meandering bending. A method for producing a meandering annular coil, wherein   A method for producing a serpentine annular coil comprising integrally mounting a synthetic resin outer body along the meandering annular shape on the outer periphery of a serpentine annular coil having a plurality of meandering portions protruding in the axial direction, An annular winding coil is meandered and bent to form a meandering annular coil molded body, and a synthetic resin exterior body is integrated along the outer periphery of the meandering annular coil molded body so as to wrap around the meandering annular coil molded body A method of manufacturing a meandering annular coil, wherein   The exterior body is formed by forming an exterior body main body having a recess into which the annular winding coil or the meandering annular coil molded body is fitted by a plastic sheet, and the annular winding coil or the serpentine annular coil molded body is formed in the recess of the exterior body main body. 6. The meandering annular coil according to claim 4 or 5, wherein in the fitted state, the opening is covered with a lid made of a plastic sheet, and the lid and the exterior body main body are bonded together. Production method.   7. The outer package body is formed by directly forming a plastic sheet softened by heating along the outer periphery of an annular winding coil or a meandering annular coil molded body by vacuum forming, pressure forming, or vacuum / pressure combined use forming. Manufacturing method of meandering annular coil   The meandering annular coil manufacturing method according to claim 6, wherein the exterior body is formed by using a mold having a recess into which an annular winding coil or a meandering annular coil molded body is fitted.   The exterior body is formed of a synthetic resin and a lower exterior body in which the lower half of the serpentine annular coil molded body is fitted and an upper exterior body in which the upper half of the serpentine annular coil molded body is fitted, 6. The serpentine ring according to claim 4 or 5, wherein the upper outer body and the upper outer body are fitted to the meandering annular coil molded body from above and below, and the edge abutting portions of the lower outer body and the upper outer body are integrally bonded. Coil manufacturing method.