CA2032327C - Method for manufacturing a spacer for a resin-molded coil, and method for manufacturing a resin-molded coil using the spacer - Google Patents

Method for manufacturing a spacer for a resin-molded coil, and method for manufacturing a resin-molded coil using the spacer

Info

Publication number
CA2032327C
CA2032327C CA002032327A CA2032327A CA2032327C CA 2032327 C CA2032327 C CA 2032327C CA 002032327 A CA002032327 A CA 002032327A CA 2032327 A CA2032327 A CA 2032327A CA 2032327 C CA2032327 C CA 2032327C
Authority
CA
Canada
Prior art keywords
resin
sheet material
spacer
manufacturing
coil
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CA002032327A
Other languages
French (fr)
Other versions
CA2032327A1 (en
Inventor
Jirou Yugami
Zenrou Hayashi
Shigeru Hirano
Koichi Hirakawa
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Panasonic Holdings Corp
Original Assignee
Matsushita Electric Industrial Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to JP1157743A priority Critical patent/JPH0322512A/en
Application filed by Matsushita Electric Industrial Co Ltd filed Critical Matsushita Electric Industrial Co Ltd
Priority to CA002032327A priority patent/CA2032327C/en
Priority to EP90124533A priority patent/EP0491070A1/en
Publication of CA2032327A1 publication Critical patent/CA2032327A1/en
Application granted granted Critical
Publication of CA2032327C publication Critical patent/CA2032327C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/12Insulating of windings
    • H01F41/127Encapsulating or impregnating

Abstract

The present invention relates to a method for manufacturing a spacer for a resin-molded coil. The method includes the steps of discharging a predetermined amount of synthetic resin on a surface of a sheet material and leaving the resin on the surface of the sheet material to cure into a solid state to form a projection made of the resin on the surface of the sheet material. An apparatus for carrying out the method includes a mounting section for mounting the sheet material, a discharging section for discharging a predetermined amount of synthetic resin onto the sheet material and a solidifying section for solidifying the discharged resin on the sheet material.

Description

METHOD FOR MANUFACTURING A SPACER
FOR A RESIN-MOLDED COIL, AND METHOD FOR
MANUFACTURING A RESIN-MOLDED COIL USING THE SPACER

The present invention relates to a method for manufacturing a spacer for a resin-molded coil, an apparatus for carrying out the method, and a method for manufacturing a resin-molded coil.
A conventional system of making resin-molded coils will be described in detail hereinbelow.
One object of the present invention is to provide a method for manufacturing a spacer for a resin-molded coil, an apparatus for carrying out the method, and a method for manufacturing the resin-molded coil itself, all of which are effective in reducing the manufacturing and mounting operations for a resin-molded spacer.
In accordance with one aspect of the present invention there is provided a method for manufacturing a spacer for a resin-molded coil, comprising the steps of: discharging a predetermined amount of synthetic resin on a surface of a sheet material; and leaving the resin on the surface of the sheet material to cure into a solid state to form a projection made of the resin on the surface of the sheet material.
The resulting product made in accordance with the present invention provides a spacer which is easy to mount onto the outer surface of the coil body and/or the inner surface of the bobbin.
In accordance with another aspect of the present invention there is provided an apparatus for manufacturing a spacer for a resin-molded coil, comprising: a mounting section for mounting a sheet material; a discharging section for discharging a predetermined amount of synthetic resin onto the sheet material; and a solidifying section for solidifying the discharged resin on the sheet material.
.
- 2 20~2327 The synthetic resin projection of the present invention can be simply formed on the sheet material to form the resin spacer. Thus, the surface of the spacer has excellent adhesion to the resin for mold.
According to a yet another aspect of the present invention, there is provided a method for manufacturing a resin-molded coil, comprising the steps of: attaching a resin projection serving as a spacer to a sheet material; mounting the sheet material onto an inner surface and/or an outer surface of a coil body; inserting the coil body into molds;
and casting resin in the molds to cover the coil body with the resin.
The present invention will be described in detail hereinbelow with the aid of the accompanying drawings, in which:
Figs. lA and lB are schematic cross-sectional views showing a resin-molded coil of the present invention;
Fig. 2 is a schematic view showing an apparatus for carrying out the method, according to one embodiment of the present invention;
Fig. 3 is a schematic view showing a conventional resin-molded coil;
Figs. 4 and 5 are a perspective view and a cross-sectional view, respectively, of molds for manufacturing the coil.
Before the description of the present invention proceeds, it is noted that like parts are designated by like reference numerals throughout the accompanying drawings.
Conventionally, in resin-molded coils, the minimum thickness of a resin layer on each of the coils has been ensured by mounting a spacer onto each of the coils.
Fig. 3 shows a schematic view thereof.
In Fig. 3, reference numeral 21 denotes a coil bobbin made of FRP. An insulating layer and a conductor are wound around the bobbin 21 to form a coil body 22. A synthetic resin spacer 23 is then mounted onto the outer circumferential surface of the coil body 22 using a double-sided adhesive tape. When it is necessary to form a resin layer at the inner circumferential surface of the bobbin 21, a synthetic resin spacer 24 is mounted onto the inner circumferential surface of the coil body 22 using a double-sided adhesive tape.
The resin spacers 23 and 24 each have a configuration such as a column, a cone, or a square pole. After the spacers are molded in molds, the surfaces of the spacers are abraded with sandpaper or are sandblasted in order to improve their adhesion to the resin which will cover the coil body. The coil is accommodated in molds for covering the coil with the resin and thereafter the resin is introduced into the molds and cured so as to form a resin layer 25 with which the coil is covered.
In the conventional coils, spacers 23 and 24 are connected to the bobbin 21 and are abraded with sandpaper or are sandblasted. As a result, it takes many manufacturing and mounting operations to obtain the resin-molded coil.
The present invention will now be described in detail.
In Figs. lA and lB, the coil comprises a coil bobbin 1, a coil body 2, a sheet material 3 supporting synthetic resin spacers 4 and 5, and a resin layer 6 which covers all the above. The coil bobbin 1 is so constructed that pre-cured epoxy resin is impregnated into a sheet material and then the impregnated sheet material is laminated to cure. The coil body 2 is so constructed that an insulating layer such as a polyester film or an aromatic polyamide paper and a conductor such as a sheet or a wire made of aluminum or copper are wound. The resin layer 6 is made by casting and curing resin between molds 9 and 10 as shown in Figs. 4 and 5 after the coil body 2 is accommodated between the molds 9 and 10. The inner mold 9 is arranged inside the outer mold 10. The outer mold 10 comprises a first mold lOa, a second mold lOb, and a third mold lOc and is formed by contacting the first to third molds lOa, lOb, and lOc with each other. In Fig. 4, reference numeral 8 denotes a lead wire and reference numeral 11' denotes a screw for fixing the wire 8 to the third mold lOc.

Epoxy resin, urethane resin, or silicone resin is suitable.
One example of the composition of the epoxy resin which is widely used as the molding resin insulator is bisphenol A type epoxy resin to which acid anhydride is added as a curing agent and into which 50-70 weight percentages of an inorganic oxide such as silica or alumina is mixed as a filler. When the composition of the resin is similar to the composition of the resin spacers 4 and 5, the electrical characteristics, the physical properties, and the adhesion properties of the finished molded portion can be improved.
Reference numeral 7 denotes a reinforcement material made of fabric of glass fibre or polyester fibre, or polyester bonded fabric each of which has excellent resin impregnation properties. In a case of the resin made of epoxy resin, a sheet material which base material is glass fibre can obtain excellent electrical insulation and physical properties. The sheet material also can be made of polyethylene terephthalate fabric when using epoxy resin as the molding resin.
Fig. 2 is a schematic view showing an apparatus for manufacturing a synthetic resin spacer.
In Fig. 2, reference numeral 11 denotes a sheet material such as a glass fibre fabric, a polyester fibre fabric, a polyester bonded fabric, or a polyester film. The sheet material 11 is supported by a roll type supporting member which preferably has a breaking mechanism. Reference numeral 12 denotes an apparatus for discharging a predetermined amount of two-pack resin such as epoxy resin to form the synthetic resin spacer. The amount discharged therefrom generally is about 0.4-2 grams and can be changed according to the configuration of the spacer. The height of the spacer, the viscosity, thixotropy, and reactivity of the resin as well as the discharging amount of the resin can all be changed. The timing of the discharge corresponds to that of the feed of the sheet material 11. The synthetic resin is discharged after stopping the feed of the sheet material 11. The apparatus comprises sections for discharging predetermined amounts of curing agent and formulated resin (mixture with resin, filler, -pigment, accelerator, and so on) and a mixer. A predetermined amount of the curing agent and a predetermined amount of the chief material are discharged from the sections and mixed in the mixer to make the fluid resin. A predetermined amount of fluid resin is then discharged from the mixer onto the surface of the sheet material 11. Reference numeral 13 denotes a projection formed by discharging the predetermined amount of fluid resin on the surface of the sheet material 11.
Reference numeral 14 denotes a heater for gelatinizing the fluid resin. An extreme infrared radiation heater can be used as the heater. In using ultraviolet curing resin for the spacer, an ultraviolet-light irradiation apparatus can be used. The sheet material 11 onto which the resin projections 15 are attached is wound as shown by reference numeral 16 in Fig. 2.
When the resin is attached to the sheet material 11 and the sheet material 11 is turned over to cure as shown in Fig. 2, there is some relationship between the discharging amount and the height of the resin in adjusting the height of the spacer because if an excessive amount of the resin is discharged onto the sheet material 11, the resin drops from the sheet material 11 when it is turned over. However, when the sheet material 11 is not turned over to cure, it is difficult to control the height of the resin projection 15 in accordance with the discharging amount of the resin and thus it is necessary to change the composition of the resin.
The layer of the molding resin which includes the spacer has insulating strength and physical properties similarly to those of the other resin layer. When reactive synthetic resin is used for the resin spacer and the molding resin, it is preferable that the reactive resin of the resin spacer be initially cured to a precured state and after the resin molding operation, the reactive resin of the resin spacer in the precured state and the molding resin are simultaneously cured to obtain excellent interface characteristics.

20~2~27 According to this embodiment, therefore, the sheet material is mounted at the inner and outer circumferential surfaces of the coil, and the sheet material has resin spacers continuously attached thereto, so the spacers are attached to the outer circumferential surface of the coil body and the inner circumferential surface of the bobbin. Therefore, this process can reduce and simplify the manufacturing operation of the resin-molded coil and prevent the spacer from dropping out of the coil during the operation.

Claims (11)

1. A method for manufacturing a spacer for use in a method of manufacturing a resin-molded coil, the method of manufacturing the resin-molded coil including steps of mounting a sheet material on an inner surface or an outer surface of a coil body or on both of said inner surface and said outer surface of the coil body, said sheet material having attached thereto a synthetic resin spacer, inserting the resulting coil body in a mold for encasing the coil body in a resin layer, and casting resin in the mold to cover the coil body with the resin layer and to obtain the resin-molded coil, said method for manufacturing a spacer comprising the steps of:
discharging a predetermined amount of synthetic resin on a surface of a sheet material; and leaving the resin on the surface of the sheet material without use of a mold to cure in a solid state in a predetermined configuration to form a projection made of the resin on the surface of the sheet material.
2. The method for manufacturing a spacer as claimed in claim 1, wherein a base material of the sheet material is glass fibre and the resin is epoxy resin.
3. The method for manufacturing a spacer as claimed in claim 1, wherein the sheet material is made of polyethylene terephthalate fabric and the resin is epoxy resin.
4. An apparatus for manufacturing a spacer for a resin-molded coil, comprising:
a mounting section for mounting a sheet material;
a discharging section for discharging a predetermined amount of synthetic resin onto the sheet material; and a solidifying section for solidifying the discharged resin on the sheet material.
5. A method for manufacturing a resin-molded coil, comprising the steps of:
mounting a sheet material onto an inner surface or an outer surface of a coil body or on both of said inner surface and said outer surface of the coil body, said sheet material having attached thereto a synthetic resin spacer, said spacer having been manufactured by discharging a predetermined amount of synthetic resin on a surface of the sheet material, and by leaving the resin on the surface of the sheet material without use of a mold to cure in a solid state in a predetermined configuration to form a projection made of the resin on the surface of the sheet material;
inserting the resulting coil body in a mold for encasing the coil body in a resin layer; and casting resin in the mold to cover the coil body with the resin and to obtain the resin-molded coil.
6. The method for manufacturing a resin-molded coil, as claimed in claim 5, wherein the sheet material is glass fiber and the resin is epoxy resin.
7. The method for manufacturing a spacer as claimed in claim 1, wherein the resin of the spacer includes 50 - 70 wt%
inorganic oxide as filler.
8. The method for manufacturing a resin-molded coil as claimed in claim 5, wherein the resin of the spacer includes 50 - 70 wt% inorganic oxide as filler.
9. The method for manufacturing a resin-molded coil as claimed in claim 5, wherein the resin of the spacer and the resin of the resin layer is epoxy resin.
10. The method of manufacturing a spacer according to claim 1, wherein the synthetic spacer resin is discharged onto an upper surface of the sheet material, and the sheet material is subsequently turned over to cure the resin in an inverted state.
11. The method of manufacturing a resin-molded coil according to claim 5, wherein the method of manufacturing the spacer includes a step of turning over the sheet material so that the resin discharged on the sheet material is cured in an inverted state.
CA002032327A 1989-06-20 1990-12-14 Method for manufacturing a spacer for a resin-molded coil, and method for manufacturing a resin-molded coil using the spacer Expired - Fee Related CA2032327C (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
JP1157743A JPH0322512A (en) 1989-06-20 1989-06-20 Manufacture of spacer for resin-molded coil, device therefor and manufacture of resin-molded coil
CA002032327A CA2032327C (en) 1989-06-20 1990-12-14 Method for manufacturing a spacer for a resin-molded coil, and method for manufacturing a resin-molded coil using the spacer
EP90124533A EP0491070A1 (en) 1989-06-20 1990-12-18 Method for manufacturing spacer for resin mold coil, apparatus for carrying out the method, and method for manufacturing resin mold coil

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP1157743A JPH0322512A (en) 1989-06-20 1989-06-20 Manufacture of spacer for resin-molded coil, device therefor and manufacture of resin-molded coil
CA002032327A CA2032327C (en) 1989-06-20 1990-12-14 Method for manufacturing a spacer for a resin-molded coil, and method for manufacturing a resin-molded coil using the spacer

Publications (2)

Publication Number Publication Date
CA2032327A1 CA2032327A1 (en) 1992-06-15
CA2032327C true CA2032327C (en) 1996-04-02

Family

ID=25674410

Family Applications (1)

Application Number Title Priority Date Filing Date
CA002032327A Expired - Fee Related CA2032327C (en) 1989-06-20 1990-12-14 Method for manufacturing a spacer for a resin-molded coil, and method for manufacturing a resin-molded coil using the spacer

Country Status (3)

Country Link
EP (1) EP0491070A1 (en)
JP (1) JPH0322512A (en)
CA (1) CA2032327C (en)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10248782B4 (en) * 2002-09-30 2005-08-04 Siemens Ag Casting mold for cylindrical cast resin coils

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AU521297B2 (en) * 1978-11-01 1982-03-25 English Electric Co. Ltd., The Encapsulated high voltage windings
US4239077A (en) * 1978-12-01 1980-12-16 Westinghouse Electric Corp. Method of making heat curable adhesive coated insulation for transformers
JPS5694713A (en) * 1979-12-28 1981-07-31 Fuji Electric Co Ltd Manufacturing method of coil spacer of resin mold type electrical apparatus
JPS56124204A (en) * 1980-03-05 1981-09-29 Hitachi Ltd Resin molded coil

Also Published As

Publication number Publication date
CA2032327A1 (en) 1992-06-15
JPH0322512A (en) 1991-01-30
EP0491070A1 (en) 1992-06-24

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