JPH09134816A - Resin molded coil and manufacturing method thereof - Google Patents

Abstract

(57) 【Abstract】 PROBLEM TO BE SOLVED: To shorten the manufacturing man-hour and manufacturing time of a resin mold coil. An inner peripheral surface 12 and an outer peripheral surface 13 of a coil 11 are provided.
Are covered with insulating prepreg sheets 18, 18, and both end surfaces 14, 14 of the coil 11 are thermoset silicone resin 19,
It is covered with 19.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin-molded coil in which the coil is covered with resin and a method for manufacturing the same.

[0002]

2. Description of the Related Art As a conventional resin mold coil, for example, there is one shown in Japanese Patent Laid-Open No. 59-43514.

In manufacturing this resin mold coil, as shown in FIG.
As shown in FIG. 1, first, the insulating prepreg sheet 18 is provided on the outer periphery of the winding form 22 attached to the winding machine 21.
Wrap around 2. Then, the winding machine 21 is driven to rotate the winding form 22, and a conductive wire is wound around the winding form 22 to form the coil 11. Subsequently, the insulating prepreg sheet 18 is also wound around the outer circumference 13 of the coil 11, and the resin-molded coil intermediate product 10 is removed together with the winding die 22 from the winding machine 21. Next, the recess A formed between the end of the insulating prepreg sheet 18 and the end surface 14 of the coil 11 is formed.
In order to fill the putty-like resin such as epoxy resin, the resin mold coil intermediate product 10 is vertically stood. That is, the resin-molded coil intermediate product 10 is placed in a drying place so that the through holes of the coil 11 face the vertical direction. This is because the viscosity of the resin once decreases in the process of thermosetting the putty resin such as the epoxy resin after that, so that the resin molded coil intermediate product 10 must be placed vertically upright.
This is because the resin drips from the recess A at the end of the coil.

When the resin-molded coil intermediate product 10 is placed in a drying place, the coiled end facing upward is filled with a putty-like resin by using a brush or a spatula, and the putty-like resin is heated. Heat cure. When the putty-like resin filled in one end is thermoset, the resin molded coil intermediate product 10 is repeated so that the other end faces upward. Similarly, the other end is filled with the putty-like resin by using a brush or a spatula, and the putty-like resin is heated to thermoset the putty-like resin. When the resin on both ends of the coil hardens, apply a grinder to the corners of the ends to remove burrs and the like,
Complete the resin mold coil.

[0005]

However, in such a conventional technique, when the resin is filled in the end portion of the coil, the intermediate product 10 of the resin mold coil is wound by the winding machine 21.
Then, this is erected vertically, one end is filled with resin, and after this resin is thermally cured, the resin molded coil intermediate product 10 is repeated repeatedly, and the same treatment is applied to the other end. Since it has to be performed, there is a problem that the number of man-hours required is extremely large and the manufacturing time is long.

In addition, since an acid anhydride curing agent is generally added to the epoxy resin, it is necessary to take care that the resin does not touch the hand during the filling work, and a grinder is used. During the deburring work, it is necessary to take measures against dust, and there is a problem that special safety measures are required for each work. Furthermore, since the epoxy resin has a very high viscosity during filling, it cannot be filled with a resin injection gun, and must be filled manually with a brush or a spatula. There is also a problem that is difficult.

The object of the present invention was made in view of the above circumstances, and is a resin mold coil which requires a small number of man-hours, a short manufacturing time, does not require a special safety measure, and is relatively easy to automate. And a method for manufacturing the same.

[0008]

In the resin mold coil for achieving the above object, at least a part (14) of the outer circumference of the coil (11, 11a) is covered with a thermosetting silicone resin (19). It is characterized by that.
Another resin-molded coil for achieving the above-mentioned object is that the inner peripheral surface (12) and the outer peripheral surface (13) of the coil (11, 11a) are covered with an insulating resin sheet, and the coil (1
Both end surfaces (14, 14) of (1, 11a) are covered with a thermosetting silicone resin (19).

Here, in the above resin mold coil, it is preferable that the thermosetting silicone resin (19) is added with an extender having flame retardancy and insulating properties.

Further, in the above resin mold coil, the coil (11a) has a wire (16) and a winding axis direction (S) in which the winding axis (25) extends around the virtual winding axis (25). ), When the conductor wire (16) is wound many times, an insulating resin sheet (18) for ensuring insulation in the winding axis direction (S), and this winding shaft around the virtual winding shaft (25) In the layer direction (R) away from (25),
Insulating material for interlayer insulation (17) for securing insulation in the layer direction (R) when winding the conductor wire (16) in multiple layers
And an insulating material (1) for interlayer insulation, which is adjacent to a part of the outer circumference of the conductor (16) and along the longitudinal direction of the conductor (16).
7) is applied, and the insulating resin sheet (18) is wound around the outer periphery of the conductor wire (16) to which the insulating material for interlayer insulation (17) is applied to form the wire material (15), and the coil (11).
a) is a winding shaft (25) so that the side of the wire (15) on which the insulating material (17) for interlayer insulation is applied faces the layer direction (R).
The wire rod (15) is wound many times in the winding axis direction (S) around the center, and the wire rod (15) is wound in multiple layers around the winding shaft (25) in the layer direction (R). It may be

Further, in the method of manufacturing a resin mold coil for achieving the above object, the insulating resin sheet is formed by covering the outer peripheral surface of the winding type (22) of the coil (11, 11a) with an insulating resin sheet (18). Wire wound type (2) covered with (18)
A conductive wire (15) is wound around the outer periphery of (2) to form a coil (11, 11a), and an outer peripheral surface (13) of the coil (11, 11a) is covered with an insulating resin sheet (18) to form a coil (11). Thermosetting silicone resin (19) is filled into both end faces (14, 14) of (11, 11a), and the thermosetting silicone resin (19) is heated to heat the silicone resin (1).
9) is cured.

In the above description, the reference numerals in parentheses are the reference numerals of the corresponding parts in the embodiments described below.

[0013]

BEST MODE FOR CARRYING OUT THE INVENTION Resin molded coils as various embodiments according to the present invention will be described below.

First, a resin mold coil according to an embodiment of the present invention will be described with reference to FIGS. As shown in FIG. 1, the resin-molded coil includes an insulating prepreg sheet 1 that covers a coil 11 formed in a substantially prismatic shape and an inner peripheral surface 12 and an outer peripheral surface 13 of the coil 11.
8 and 18, and thermosetting silicone resin 19 that covers both end surfaces 14 and 14 of the coil 11.

In the manufacture of this resin mold coil, as shown in FIG.
As described in the related art with reference to FIG. 1, first, the substantially prismatic winding die 22 is attached to the rotary shaft 21 a of the winding machine 21. Subsequently, the insulating prepreg sheet 18 is wound around the outer periphery of the winding die 22. This insulating prepreg sheet 18
Is a glass cloth impregnated with an epoxy resin.
Then, while driving the winding machine 21 to rotate the winding die 22, the wire rod is wound in the winding axis direction S about the virtual winding shaft 25 formed on the extension line of the rotating shaft 21a of the winding machine 21. Roll up. When the first layer is finished winding, the interlayer insulation sheet
After performing (not shown), a wire is further wound around the outer circumference to form a second layer, and the outer circumference is also covered with an interlayer insulating sheet. The above process is repeated several times to wind the wire rod in multiple layers in the layer direction R away from the winding shaft 25 to form the coil 11. When the coil 11 is formed, the insulating prepreg sheet 1 is also formed on the outer peripheral surface 13 of the coil 11.
Wrap 8 Here, the inner peripheral surface 12 and the outer peripheral surface 13 of the coil 11 provided with the insulating prepreg sheet 18 is referred to as a resin molded coil intermediate product 10.

In the resin-molded coil intermediate product 10, the length of the insulating prepreg sheet 18 on the inner and outer circumferences in the winding axis direction S is longer than the length of the coil 11 in the winding axis direction S, and the end surface 14 of the coil 11 is formed. , 14 and the insulating prepreg sheets 18, 18 on the inner and outer circumferences form a recess A. Next, as shown in FIG. 3, the thermosetting silicone resin 19 is filled into the recess A at the end of the resin molded coil intermediate product 10 using the resin injection gun 23. At this time, the winding machine 21 is driven to drive the resin-molded coil intermediate product 1
While rotating 0, the thermosetting silicone resin 19 is filled.

Next, the resin mold coil intermediate product 10a, which has been filled with the thermosetting silicone resin, is used as the winding type 2
The two are removed from the winding machine 21, and as shown in FIG. 4, they are laid side by side on a drying plate 26 laid with a Teflon separate sheet 27. The resin-molded coil intermediate product 10a can be placed horizontally because the thermosetting silicone resin has such a viscosity that it does not drip from the recess A of the resin-molded coil intermediate product 10 at room temperature and the heat to be applied later. This is because the viscosity does not decrease unlike the epoxy resin during the curing process. When a fixed number of the resin molded coil intermediate products 10a are finished, the Teflon separate sheet 27 is laid again on them, and the resin molded coil intermediate product 10a is placed on this. As described above, a plurality of resin mold coil intermediate products 10a, 10a, ... Are stacked on the drying plate 26 in a plurality of stages.
Then, put all of them in a drying oven and put them at 130-150.
The temperature is increased to about 0 ° C., and the thermosetting silicone resin 19 filled in the end portion of the coil 11 is cured together with the insulating prepreg sheets 18, 18 arranged on the inner and outer circumferences of the coil 11. As described above, since the plurality of resin mold coils 10a, 10a, ... Filled with the thermosetting silicone resin can be stacked in a plurality of stages and cured at one time, the drying furnace can be efficiently used.

After the insulating prepreg sheet 18 and the thermosetting silicone resin 19 are cured, the winding die 22 is removed and a shaping operation is performed to complete the resin mold coil shown in FIG. In this shaping operation, using a cutter knife,
Chamfer the corner of the coil.

As described above, in the manufacture of this resin-molded coil, both end surfaces 14, 14 of the coil 11 can be filled with the resin at a time, and the inner and outer peripheral surface 1 of the coil 11 can be filled.
Since the thermosetting silicone resin 19 filled in both end surfaces 14 and 14 of the coil 11 can be cured in one step together with the insulating prepreg sheets 18 and 18 arranged in 2 and 13, the number of work steps can be reduced. In addition, the manufacturing time can be shortened. Further, since the silicone resin is viscous with respect to curing shrinkage, internal residual stress does not occur and there is no problem such as cracks, so that it can be cured for a short time and gradually cooled for a short time. Therefore, also from this aspect, the manufacturing time can be shortened.

Since the thermosetting silicone resin 19 is harmless to the human body, it is not necessary to take care that it does not come into contact with the skin. Furthermore, since the deburring work by the grinder is eliminated, dust collection is possible. No measures are required. Therefore, safety measures for each work are facilitated and the manufacturing cost can be reduced. Further, the thermosetting silicone resin 19 is used for the resin mold coil 1 as described above.
Even if 0 is placed horizontally and the concave portion A at the end thereof is filled with this silicone resin, it has a viscosity that does not drip, but since it has a lower viscosity than the epoxy resin, the resin injection gun 23 is used when filling the resin. It can be used, and the filling operation can be facilitated and the filling operation can be automated.

Further, as a wire insulating material for covering the outer periphery of the conductor wire and an interlayer insulating material for insulating the layers of the coil 11,
For example, polyester films (polyethylene terephthalate), polyethylene naphthalate, and other chemically additive films may be used. In this case, deterioration may be promoted by the acid anhydride curing agent added to the epoxy resin. However, when a silicone resin is used, it is harmless to these films and is very advantageous for long-term insulation deterioration.

As a filler for the end surface 14 of the coil 11,
Replacement of conventional epoxy resin, thermosetting silicone resin 1
As described above, the use of No. 9 has many advantages, but at the present time, the thermosetting silicone resin 19 is more expensive than the epoxy resin. Furthermore, since the cured silicone resin is rubbery and soft, the user may feel uneasy due to the feel of the finger. Therefore, the amount of the thermosetting silicone resin 19 which is relatively expensive is added by adding to the thermosetting silicone resin 19 an inexpensive material that is harder than the silicone resin and has flame retardancy and insulation properties, as an extender. It is preferable to reduce the manufacturing cost and increase the feel of the finger. Specifically, 80% Wt of quartz powder is added to the thermosetting silicone resin 19 as a filler. The price of this quartz powder is about 1/2 of that of ordinary silicon resin at present, and the manufacturing cost can be sufficiently reduced.

By the way, when an experiment was conducted using a silicon resin to which 80% Wt of quartz powder was added, the filling work with the resin injection gun 23 was satisfactory although the viscosity increased to some extent. Further, the curing time is 110 to 120 ° C. and 3 to 5
The desired properties were obtained over time. The hardness of the cured product to which the quartz powder was added was higher than the hardness of the cured product to which the quartz powder was not added, and a Shore hardness of 80 ° or more was obtained. In addition, JI which is generally used as an index of flame retardancy
When tested with the flame resistance (method A) described in SK6911 (1979) (General test method for thermosetting plastics), the product with 80% Wt quartz powder has a burning time of 0 (seconds) and a burning distance of 5 (mm). Therefore, it was nonflammable as a flame retardant category. As a comparison, in a similar flame resistance test of a cured product of an epoxy resin to which a general acid anhydride curing agent and crystalline quartz powder are added, a burning time is 12 to 14 (seconds) and a burning distance is 11
It was about 14 (mm). In these flammability tests, both are nonflammable as a combustion category, but 80% quartz powder
It can be said that the silicon resin added with Wt has improved flame retardancy as compared with the epoxy resin.

Next, a resin molded coil as another embodiment according to the present invention will be described with reference to FIGS. In this embodiment, as shown in FIG.
As the wire material 15 forming the coil 11a, a conductor wire 16 which is the main body of the wire material 15, an insulating material 17a for interlayer insulation, which is adjacent to a part of the outer circumference of the conductor wire 16 and is provided along the longitudinal direction of the conductor wire 16, Insulating resin sheet 1 wrapped around the outer circumference of the conductor 16 provided with the insulating material 17a for interlayer insulation
7b is used.

The insulating resin sheet 17b is a virtual winding shaft 2
When the conductor wire 16 is wound many times in the winding axis direction S in which the winding shaft 25 extends around the center 5, the insulating property between the adjacent conductor wires 16 and 16 in the winding axis direction S is secured. In addition, the insulating material 17a for interlayer insulation is an insulating property between the conductor wires 16 and 16 adjacent to each other in the layer direction R when winding the conductor wire 16 in a plurality of layers in the layer direction R away from the winding shaft 25 around the virtual winding shaft 25. To secure. In the coil 11a, the potential difference between the conductors adjacent to each other in the layer direction R is larger than that between the conductors adjacent to each other in the winding axis direction S.
The insulating material 17a for interlayer insulation has higher insulation than 7b. In this embodiment, the insulating resin sheet 17b
The insulating material 17a for interlayer insulation is also formed of a prepreg sheet.

In this embodiment, the wire rod 1 described above is used.
5, the insulating material 17 for interlayer insulation is used as shown in FIG.
The wire rod 15 is wound many times around the winding type (not shown) in the winding axis direction S so that the side to which a is applied faces the layer direction R, and further, the wire rods 15 are wound in multiple layers in the layer direction R. Is wound to form the coil 11a. As described above, by using the wire 15 to which the insulating material 17a for interlayer insulation is applied in advance, it is possible to save the labor of arranging the interlayer insulating sheet after forming each layer in the coil forming process.

Also in this imprisoned form, the coil 11a formed as described above is used, like the previous embodiment,
An insulating prepreg sheet 18 is formed on the inner and outer circumferences of the coil 11a.
18 is arranged, and thermosetting silicone resin 19 is applied to both ends of the coil 11a to form a resin mold coil. Therefore, in addition to the effect of omitting the step of applying the interlayer insulating sheet described above, the same effect as that of the previous embodiment can be obtained.

[0028]

According to the present invention, both end faces of the coil can be filled with the resin at a time, and the filled resin can be cured in one step, so that the number of working steps can be reduced. Manufacturing time can be shortened. In addition, since the thermosetting silicone resin that fills the end surface of the coil is harmless to the human body, it is not necessary to take care that it does not touch the skin, and since deburring work with a grinder is eliminated, No need for dust collection measures. Therefore, safety measures for each work are facilitated and the manufacturing cost can be reduced. Further, since the thermosetting silicone resin has a lower viscosity than the conventionally used epoxy resin, a resin injection gun can be used at the time of resin filling, which facilitates the filling work and aims at automation of the filling work. You can also

[Brief description of the drawings]

FIG. 1 is a vertical cross-sectional view of a resin mold coil according to an embodiment of the present invention.

FIG. 2 is a vertical cross-sectional view of an intermediate product of a resin molded coil as an embodiment according to the present invention.

FIG. 3 is a perspective view showing a silicon resin filling operation of a resin mold coil according to an embodiment of the present invention.

FIG. 4 is a perspective view showing a posture of the resin molded coil as a first embodiment according to the present invention during curing.

FIG. 5 is a vertical sectional view of a resin mold coil as another embodiment according to the present invention.

FIG. 6 is a cross-sectional view of a wire used in a resin mold coil according to another embodiment of the present invention.

[Explanation of symbols]

10 ... Resin mold coil intermediate product, 11, 11a ...
Coil, 12 ... Inner surface, 13 ... Outer surface, 14 ... End surface, 1
5 ... Wire material, 16 ... Conductive wire, 17a ... Insulation material for interlayer insulation, 1
7b ... Insulating resin sheet, 18 ... Insulating prepreg sheet, 19 ... Thermosetting silicone resin, 21 ... Winding machine, 22
... winding type, 25 ... winding shaft.

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[Procedure amendment]

[Submission date] January 26, 1996

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] 0022

[Correction method] Change

[Correction contents]

As a filler for the end surface 14 of the coil 11,
Instead of conventional epoxy resins, the use of the thermosetting silicone resin 19, as described above, although there are many advantages, at present, thermosetting silicone resin 19 as compared with the epoxy resin, expensive There is also a drawback that is. Furthermore, since the cured silicone resin is rubbery and soft, the user may feel uneasy due to the feel of the finger.
Therefore, the amount of the thermosetting silicone resin 19 which is relatively expensive is added by adding to the thermosetting silicone resin 19 an inexpensive material that is harder than the silicone resin and has flame retardancy and insulation properties, as an extender. It is preferable to reduce the manufacturing cost and increase the feel of the finger. Specifically, 80% Wt of quartz powder is added to the thermosetting silicone resin 19 as a filler. Thus obtained resin <br/> is the price, the about half of the conventional silicon resin containing no filler, it is possible to sufficiently reduce manufacturing costs.

[Procedure amendment 2]

[Document name to be amended] Statement

[Correction target item name] 0027

[Correction method] Change

[Correction contents]

Also in this embodiment , by using the coil 11a formed as described above, as in the previous embodiment,
An insulating prepreg sheet 18 is formed on the inner and outer circumferences of the coil 11a.
18 is arranged, and thermosetting silicone resin 19 is applied to both ends of the coil 11a to form a resin mold coil. Therefore, in addition to the effect of omitting the step of applying the interlayer insulating sheet described above, the same effect as that of the previous embodiment can be obtained.

Claims (5)

[Claims] 1. A resin-molded coil in which the periphery of the coil is covered with resin, wherein at least a part of the outer periphery of the coil is covered with a thermosetting silicone resin. 2. A resin-molded coil in which the coil surrounding is covered with a resin, wherein an inner peripheral surface and an outer peripheral surface of the coil are covered with an insulating resin sheet, and both end surfaces of the coil are made of a thermosetting silicone resin. A resin molded coil that is covered. 3. The resin-molded coil according to claim 1, wherein the thermosetting silicone resin contains a flame retardant and insulating extender added thereto. 4. The resin-molded coil according to claim 1, 2 or 3, wherein the coil has a conductor wire and the conductor wire in a winding axis direction extending around the virtual winding axis. When winding also, an insulating resin sheet for ensuring insulation between the conductors adjacent to each other in the winding axis direction, and a layer direction away from the winding axis around the virtual winding axis,
An insulating material for inter-layer insulation for ensuring insulation between adjacent conductors in the layer direction when winding the conductor in a plurality of layers, and is adjacent to a part of the outer periphery of the conductor and the longitudinal direction of the conductor. Along the direction, the insulating material for interlayer insulation is applied, the insulating resin sheet is wound around the outer periphery of the conductor wire provided with the insulating material for interlayer insulation, a wire is formed, and the coil is The wire is wound around the winding axis many times in the winding axis direction such that the side of the wire on which the insulating material for interlayer insulation is applied faces the layer direction, and the layer is wound around the winding axis. A resin molded coil, wherein the wire rod is formed by winding the wire rod in multiple layers in a direction. 5. A method of manufacturing a resin-molded coil, wherein a coil surrounding is covered with a resin, wherein the outer peripheral surface of the coil of the coil is covered with an insulating resin sheet, and the coil is covered with the insulating resin sheet. The outer periphery of, to form a coil by winding a conductive wire, the outer peripheral surface of the coil is covered with the insulating resin sheet, both ends of the coil filled with thermosetting silicone resin,
A method for producing a resin mold coil, characterized in that the thermosetting silicone resin is heated to cure the thermosetting silicone resin.