JP2009148141A - Magnetic parts - Google Patents

Abstract

An object of the present invention is to provide a magnetic part that has a coil exposed part that is not coated with resin on a coil molded body combined with a magnetic core, has good heat dissipation, suppresses manufacturing costs, and has high manufacturing efficiency. .
A magnetic part is formed by combining a coil molded body 10 and a magnetic core 20 formed by integrating a coil 11 and a resin 12, and the magnetic core of the coil molded body 10 is provided. The portion that does not come into contact with 20 is formed as a coil exposed portion 13 with the coil 11 exposed without being covered with the resin 12. When the magnetic body core 20 is the stator core of the split stator 1 of the motor, the exposed portion of the coil molded body 10 is the rotor-side end surface of the coil molded body 10 fitted into the stator core.
[Selection] Figure 1

Description

  The present invention relates to a magnetic part configured by combining a coil molded body and a magnetic core.

Conventionally, as a magnetic part used as a stator of a motor or the like, a combination of a coil molded body in which the entire circumference of a coil is covered with a resin and a magnetic core is generally used. As such a thing, there exists the following patent document 1, for example.
The split stator of the electric motor shown in Patent Document 1 has no fear of damaging the coil coating when combining the split stator, and can improve the coil space factor while ensuring good roundness of the stator. There are benefits.
JP 2007-143324 A

  However, as for the coil molded object used for the split stator shown in the above-mentioned patent document 1, the whole circumference is covered with resin. In other words, the portion of the coil molded body that does not contact the magnetic core does not require insulation, but that portion is also covered with resin. Therefore, there has been a problem that the heat dissipation of the coil molded body is poor. In addition, an extra resin is required, and the structure for holding the coil in the air in the mold is complicated.

  Therefore, the present invention solves the above-mentioned conventional problems, and has a structure in which a coil molded body combined with a magnetic core has a coil exposed portion that is not covered with resin, has good heat dissipation, suppresses manufacturing costs, and improves manufacturing efficiency. The issue is to provide good magnetic parts.

  The magnetic component of the present invention is a magnetic component configured by combining a coil molded body in which a coil and a resin are integrated and a magnetic core, and among the coil molded bodies, The first feature of the non-contact portion is that the coil is exposed without being covered with resin.

  According to the first feature of the present invention, the portion of the coil molded body that does not contact the magnetic core is a coil exposed portion where the coil is exposed without being covered with resin. Therefore, in the coil molded body, the portion that does not come into contact with the magnetic core does not need to be insulated with resin. By using this portion as a coil exposed portion, it has sufficient insulation performance and can improve heat dissipation. It can be a magnetic part. In addition, the amount of resin used can be reduced as compared with the case where the entire circumference of the coil is covered with resin, and a magnetic component with reduced manufacturing costs can be obtained.

  Further, in the magnetic component of the present invention, in addition to the first feature of the present invention described above, the magnetic core is a stator core of a split stator of a motor, and an exposed portion of the coil molded body is a coil molding that is fitted into the stator core. The second feature is that it is the rotor side end face of the body.

  According to the second feature of the present invention, in addition to the function and effect of the first feature of the present invention, the magnetic core is a stator core of a split stator of a motor, and the exposed portion of the coil molded body is a stator core. It is set as the structure which is a rotor side end surface of the coil molded object inserted by. Therefore, when the magnetic core is a stator core of a split stator of a motor, sufficient insulation performance can be obtained by making the coil-exposed portion the rotor-side end surface that does not contact the magnetic core and does not require insulation. And a magnetic component capable of improving heat dissipation. In addition, the amount of resin used can be reduced as compared with the case where the entire circumference of the coil is covered with resin, and a magnetic component with reduced manufacturing costs can be obtained.

  In addition to the first or second feature, the magnetic component of the present invention has a coil exposed portion of the coil molded body when the magnetic core is a linear magnetic core such as a transformer or a reactor. The third feature is that both end faces are used.

  According to the third feature of the present invention, in addition to the operational effects of the first or second feature, when the magnetic core is a linear magnetic core such as a transformer or a reactor, the coil exposure is performed. The portion is configured to be both end faces of the coil molded body. Therefore, when the magnetic core is a linear magnetic core such as a transformer transformer or a reactor, both ends of the coil molded body that do not come into contact with the magnetic core and do not require insulation are used as the coil exposed portions. It can be set as the magnetic body component which has sufficient insulation performance and can improve heat dissipation. Further, compared to the case where the entire circumference of the coil is coated with resin, the amount of resin used can be reduced, and a magnetic part with reduced manufacturing costs can be obtained.

  According to the magnetic component of the present invention, the coil molded body combined with the magnetic core has a coil exposed portion that is not covered with resin, so that heat dissipation is good, manufacturing cost is reduced, and manufacturing efficiency is improved. It can be a good magnetic part.

  A magnetic component according to an embodiment of the present invention will be described with reference to the following drawings to provide an understanding of the present invention. However, the following description is an embodiment of the present invention, and does not limit the contents described in the claims.

  FIG. 1 is an exploded perspective view of a split stator according to the first embodiment of the present invention. FIG. 2 is an overall perspective view of the split stator according to the first embodiment of the present invention. FIG. 3 is a view showing a manufacturing process of the coil molded body according to the first embodiment of the present invention. FIG. 4 is a horizontal sectional view of FIG. FIG. 5 is an overall perspective view showing a transformer transformer according to a second embodiment of the present invention. FIG. 6 is an overall perspective view showing a reactor according to the third embodiment of the present invention.

  First, the divided stator 1 according to the first embodiment of the present invention will be described with reference to FIGS.

  With reference to FIGS. 1 and 2, the split stator 1 according to the first embodiment of the present invention constitutes a motor stator by abutting the side surfaces and arranging and assembling in a ring shape. is there. As shown in FIGS. 1 and 2, the split stator 1 includes a coil molded body 10 and a magnetic core 20.

  The coil molded body 10 constitutes the split stator 1 by being fitted into the magnetic core 20. As shown in FIGS. 1 and 2, the coil molded body 10 includes a coil 11 and a resin 12.

As shown in FIG. 3, the coil 11 is a flat wire edgewise winding coil. The coil 11 is covered with a resin 12 to form a coil molded body 10. That is, as shown in FIG. 3, the coil 11 is first pressed from above by the pin jig 31 in a state where the coil 11 is disposed in the mold 30. Then, the resin 12 is injected into the mold 30 in a state where the adjacent flat portions 11a of the rectangular wire are in close contact with each other in the coil axis direction, although not shown in detail in FIG.
That is, as shown in FIGS. 3B and 4, the resin 12 is injected into the mold 30 with the lower end surface 11 b of the coil 11 in close contact with the mold 30. Therefore, only the upper end surface 11c, the outer peripheral surface 11d, and the inner peripheral surface 11e of the coil 11 are covered with the resin 12, and the lower end surface 11b is not covered with the resin 12. Therefore, the coil exposed portion 13 can be formed with the coil exposed without the lower end surface 11 b of the coil molded body 10 being covered with the resin 12.

Although not shown in detail in FIG. 3B, the resin 12 covering the inner peripheral surface 11e has the same shape and substantially the same shape as the outer peripheral surface of the tooth portion 21 as shown in FIGS. It is coated so as to be a size. With this configuration, it is possible to prevent a gap from being generated between the coil molded body 10 and the magnetic core 20 when the coil molded body 10 is fitted into the magnetic core 20.
The coil molded object 10 is shape | molded through the above process.

  As described above, the coil 11 is placed in the mold 30 with the lower end surface 11 b of the coil 11 in close contact with the mold 30, and the resin 12 is injected into the mold 30. The structure of the mold 30 can be simplified. Therefore, a manufacturing process can be simplified and manufacturing efficiency can be improved.

  Further, as shown in FIG. 3B, the resin 12 is injected while the lower end surface 11b of the coil 11 is brought into close contact with the flat portion of the mold 30 and pressed from above by the pin jig 31. The coil exposed portion 13 can be a flat surface. Accordingly, as shown in FIGS. 1, 2, and 4, the rotor-side end surface 21 a of the tooth portion 21 is a flat surface, and when the coil molded body 10 is fitted into the magnetic core 20, the coil exposed portion 13 and the tooth portion. 21 can be flush with the rotor-side end surface 21a. In addition, as shown in FIGS. 1 and 2, the resin 12 that covers the inner peripheral surface 11 e is coated so as to have the same shape and substantially the same size as the outer peripheral surface of the tooth portion 21. Therefore, when the coil molded body 10 is fitted into the magnetic core 20, there is no gap between the coil molded body 10 and the magnetic core 20. Therefore, no air layer is formed on the split stator 1. Therefore, the divided stator 1 having excellent heat dissipation can be obtained.

The coil molded body 10 is in a state in which the adjacent flat portions 11a of the wound rectangular wire are in close contact with each other in the coil axis direction. Thus, the heat conduction between the rectangular wires can be improved because the adjacent flat portions 11a of the wound rectangular wires are in close contact with each other in the coil axis direction. Therefore, the heat dissipation of the coil molded body 10 can be improved.
Further, the adjacent flat portions 11a of the wound rectangular wire are covered with the resin 12 in a state of being in close contact with each other in the coil axis direction. Therefore, the resin 12 covers the upper end surface 11c, the outer peripheral surface 11d, and the inner peripheral surface 11e of the coil 11 without penetrating between adjacent flat surfaces of the rectangular wire wound around the coil 11. Therefore, the coil 11 is covered with the resin 12 so that no gap is generated in the coil molded body 10. Therefore, the coil molded body 10 does not have an insulating portion called air, the heat conduction is improved by the resin 12, and the coil 11 can be protected from the refrigerant.

  Further, as shown in FIGS. 1 and 2, when the coil molded body 10 is fitted into the magnetic core 20, the rotor-side end surface of the coil molded body 10 is a portion that does not contact the magnetic core 20. Thus, the portion that does not contact the magnetic core 20 does not need to be insulated. Therefore, the coil molded body 10 is provided with the coil exposed portion 13 and is fitted into the magnetic core 20 with the coil exposed portion 13 as the end surface on the rotor side, thereby providing sufficient insulation performance and improving heat dissipation. The divided stator 1 can be obtained. Further, compared to the case where the entire circumference of the coil 11 is covered with the resin 12, the amount of the resin 12 used can be reduced, and the divided stator 1 can be manufactured with reduced manufacturing costs.

In addition, as resin 12, what is normally used as mold resin, such as thermosetting resins, such as an epoxy resin, and a thermoplastic resin, can be used.
Further, as the flat wire, a flat wire in which an insulating layer such as enamel is formed along the outer peripheral surface of a conducting wire having a rectangular cross section made of a conductive material such as copper used for a normal coil is used. it can. The size, thickness, etc. can be changed as appropriate.
In the first embodiment, the coil 11 is pressed with the pin jig 31 when the coil molded body 10 is formed. However, the configuration is not such that the coil 11 is not pressed. Of course.

The magnetic core 20 is a stator core that constitutes the split stator 1. As shown in FIGS. 1 and 2, the magnetic core 20 includes a tooth portion 21 and a yoke portion 22 in the same manner as a stator core of an ordinary split stator, and has an outer shape that is substantially T-shaped. As shown in FIG. 2, the coil molded body 10 is externally inserted into the tooth portion 21. Further, the teeth portion 21 is arranged to face a permanent magnet disposed on the outer peripheral surface of the rotor not shown in detail in FIGS.
As shown in FIGS. 1 and 2, the magnetic core 20 is formed by laminating a plurality of thin electromagnetic steel plates.

  Next, with reference to FIG. 5, a transformer 100 according to a second embodiment of the present invention will be described.

  Referring to FIG. 5, in a transformer 100 according to the second embodiment of the present invention, the coil exposed portion 13 of the coil molded body 10 in the split stator 1 according to the first embodiment of the present invention is represented by the upper and lower end surfaces 11b, 11c, and the magnetic core 20 is a magnetic core constituting the transformer. Other configurations are the same as those of the split stator 1 according to the first embodiment of the present invention. The same member and the same function are given the same number, and the following description is omitted.

  Thus, by making the magnetic core 20 into the magnetic core 20 constituting the transformer 100, when the coil molded body 10 is fitted into the magnetic core 20, as shown in FIG. Where the upper and lower end surfaces 11b and 11c are portions that do not come into contact with the magnetic core 20, the upper and lower end surfaces 11b and 11c of the coil molded body 10 are used as the coil exposed portions 13, thereby providing sufficient insulation performance and heat dissipation. The transformer 100 can be improved. Further, compared to the case where the entire circumference of the coil 11 is covered with the resin 12, the amount of the resin 12 used can be reduced, and the transformer 100 can be manufactured with reduced manufacturing costs.

  Next, a reactor 200 according to a third embodiment of the present invention will be described with reference to FIG.

  Referring to FIG. 6, a reactor 200 according to the third embodiment of the present invention includes upper and lower end surfaces 11 b and 11 c at the coil exposed portion 13 of the coil molded body 10 in the split stator 1 according to the first embodiment of the present invention. And the magnetic core 20 is a magnetic core 20 constituting a reactor. Other configurations are the same as those of the split stator 1 according to the first embodiment of the present invention. The same member and the same function are given the same number, and the following description is omitted.

  In this way, when the magnetic core 20 is used as the magnetic core 20 constituting the reactor 200, when the coil molded body 10 is fitted into the magnetic core 20, as shown in FIG. Where the end surfaces 11b and 11c are portions that do not come into contact with the magnetic core 20, the upper and lower end surfaces 11b and 11c of the coil molded body 10 are provided with the coil exposed portions 13 to provide sufficient insulation performance and improve heat dissipation. The reactor 200 can be made. Further, compared to the case where the entire circumference of the coil 11 is covered with the resin 12, the amount of the resin 12 used can be reduced, and the reactor 200 with reduced manufacturing cost can be obtained.

  The present invention can be used for an electric motor that requires various coils as magnetic parts such as a motor.

It is a disassembled perspective view of the division | segmentation stator which concerns on the 1st Embodiment of this invention. 1 is an overall perspective view of a split stator according to a first embodiment of the present invention. It is a figure which shows the manufacture process of the coil molded object which concerns on the 1st Embodiment of this invention. FIG. 3 is a horizontal sectional view of FIG. 2. It is a whole perspective view which shows the transformer transformer which concerns on the 2nd Embodiment of this invention. It is a whole perspective view which shows the reactor which concerns on the 3rd Embodiment of this invention.

Explanation of symbols

1 Split stator 10 Coil molded body 11 Coil 11a Flat surface 11b Lower end surface 11c Upper end surface 11d Outer peripheral surface 11e Inner peripheral surface 12 Resin 13 Coil exposed portion 20 Magnetic body 21 Teeth portion 21a Rotor side end surface 22 York portion 30 Mold 31 Pin jig 100 Transformer transformer 200 Reactor

Claims (3)

  A magnetic part configured by combining a coil molded body formed by integrating a coil and a resin and a magnetic core, and a portion of the coil molded body that does not contact the magnetic core is made of resin. A magnetic part having a coil exposed portion in which the coil is exposed without being covered with a coil.   2. The magnetic part according to claim 1, wherein the magnetic core is a stator core of a divided stator of a motor, and the exposed portion of the coil molded body is a rotor side end surface of the coil molded body fitted into the stator core. .   2. The magnetic part according to claim 1, wherein when the magnetic core is a linear magnetic core such as a transformer or a reactor, the coil exposed portions are both end faces of the coil molded body.

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