JP2000049026A - Electromagnetic apparatus - Google Patents

Abstract

PROBLEM TO BE SOLVED: To shorten a line, to reduce workers and to reduce labor for maintenance operations by using a 2-stage setting bond which sets in two stages, at normal temperature and under heating, as a bond while heating is done by a self-heat-accumulation at actual use. SOLUTION: In order to combine an arc protruding surface part 27 formed on both ends of a central leg iron-core 25 which is a joint part to an arc recessed surface part 32 formed on the inside surface at both ends of an almost- square side-leg lamination iron-core 30, a 2-stage setting bond which sets in two stages, at normal temperature and under heat, is applied to the arc protruding surface part 27 of the central leg iron-core and the arc recessed surface part 32 of the side-leg lamination iron-core. The arc protruding surface parts 27 and 27 of the central leg lamination iron-core are aligned with the arc recessed surface parts 32 and 32 formed on the inside surface at both ends of the side-lag lamination iron-core for press-insertion, assembling a transformer 5. Here, after setting at normal temperature as a first stage, a final setting is done by the temperature of a ballast itself when a lamp turns on for actual use, as a second stage.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to an electromagnetic device such as a ballast used for a fluorescent lamp.

[0002]

2. Description of the Related Art A ballast as a conventional electromagnetic device will be described with reference to a process of a glow start type 40W transformer type fluorescent lamp ballast manufacturing line shown in FIG.

FIGS. 9 and 10 show the structure of a transformer. As a first step, an electric wire 8 is wound around a main bobbin 11 and an electric wire is wound around a main coil 10 (hereinafter referred to as a “P coil”) and an auxiliary bobbin 21. 8 and an auxiliary coil 20 (hereinafter referred to as "S coil").

[0004] As a second step, a fitting hole 1 formed on the center line of each of the P coil 10 and the S coil 20 is formed.
The center leg laminated iron cores 25 are fitted into the cores 2 and 12 and assembled.

As a third step, the joint P
Arc-shaped convex portions 27 formed at both ends of the center leg iron core 25 combined with the coil and the S coil, and arc-shaped concave portions 32 formed at the center inner side surfaces of both ends of the side leg laminated iron core 30 having a substantially rectangular shape. After the adhesive is applied to the arc-shaped convex portion 27 of the center leg core and the arc-shaped concave portion 32 of the side leg laminated core, respectively, the arc-shaped convex portion 2 of the center leg core is joined.
The transformer 5 is assembled by press-fitting 7, 27 into arcuate concave portions 32, 32 formed on the inner surfaces of both ends of the side leg laminated core.

In a fourth step, the terminal covers 4, 4 and the bottom plate 2 shown in FIG.
As shown in FIG. 5, an adhesive is provided on an air gap portion 40 formed between the path portion 28 of the center leg laminated core and the tip of the path portion 34 of the side leg laminated core to suppress vibration and noise generated from the air gap portion. Inject.

Next, a method for injecting an adhesive into the air gap from the adhesive injecting machine using an adhesive injecting machine (not shown) will be described with reference to FIGS.
The adhesive injection jig is used by being attached to the tip of an adhesive injection machine.

An adhesive injection jig 60 includes an adhesive injection port 63 provided at the center of the upper end face 61 and front end faces 62 and 6 on both sides.
2, a pair of adhesive outlets 64, 64, an adhesive inlet 63, and a pair of adhesive outlets 64, 64, and an adhesive flow path branched bifurcated from side to side from the middle. 65
It is composed of

The adhesive outlet 64 is formed at the front end face 62 at the longitudinal center of the air gap 40 and with the center of the width of the gap as a center. Further, the adhesive outlet 64 has a diameter larger than the width of the air gap portion 40.

The tip end surface 62 of the adhesive injection jig having the adhesive outlet 64 formed thereon is formed in a flat surface so as to contact the upper surfaces of the center leg laminated core 25 and the side leg laminated core 30. At the same time, the tip shape of the adhesive injection jig 60 is formed so as to match the outer surface of the opposed flange so that the adhesive does not escape when the adhesive 70 is injected into the air gap portion 40.

The left and right tip surfaces 62 of the adhesive injection jig 60,
62, a pair of adhesive outlets 64, 6 formed respectively.
4 are formed on both sides of the transformer.
It is placed on the upper surface of the center leg laminated core 25 and the side leg laminated core 30 according to 0 and 40.

Then, when the adhesive 70 flows through the adhesive flow path 65 of the adhesive injection jig, the adhesive flows through the adhesive flow path, and the adhesive 70 flows into the air gap portion 40, and An adhesive is filled in the section.

In a fifth step, as shown in FIG. 8, the ballast 1 is assembled by tightening and fixing the case 3 to the bottom plate 2 with screws 7 and by tightening the bottom plate 2 to the terminal cover 4. Then, before heating the ballast 1, a characteristic test of the ballast is performed as a pre-heating test.

As a sixth step, a ballast is passed through an induction heating furnace and a heat insulation furnace in order to cure the adhesive applied to the joint portion and the adhesive injected into the air gap portion 40. Then, after performing a characteristic test as a final test of the ballast again, a nameplate (not shown) is attached to the lower surface of the bottom plate and packed.

[0015]

As described above, the laminated iron core of a transformer as a conventional electromagnetic device is connected to a joint portion or to suppress the vibration and noise of an air gap by force. An adhesive is indispensable for use, and the adhesive needs to have high hardness and heat resistance.

However, since the adhesive having good heat resistance has a high heating temperature at the time of curing, a dedicated heating line is provided, and a thermosetting adhesive is used as the adhesive.

The transformer is assembled by injecting the thermosetting adhesive into the air gap and applying the thermosetting adhesive to the joint. Then, assemble the transformer into the case and assemble the ballast,
The ballast was passed through an induction heating furnace and a heat insulation furnace to heat and cure the adhesive.

However, when the ballast is heated, the viscosity of the adhesive temporarily decreases, and a part of the adhesive contained in the air gap portion flows out, and the characteristics may be shifted. For this reason, the characteristic test of the ballast is required before and after heating, respectively, and the characteristic test has been performed twice in total. In addition, the dripping of the heat-curable adhesive affected noise and vibration.

The line for the induction heating furnace, the subsequent heat insulation furnace and the cooling line occupies about one third of the entire production line, so that the production line becomes long, and accordingly, human labor is required.

In addition, the adhesive softens immediately before curing, so that the adhesive drips on the production line, and as a result, the production line becomes dirty, which causes a line trouble and requires maintenance of the line.

In order to solve this problem, it is necessary to stop the production line. As a result, in-process inventory is produced, and manual labor is required to re-enter the inventory.

In addition, since there are time and line lengths for heating, warming and cooling, the ballast is not completely cooled, and the characteristic inspection and packing work of the product are performed in a hot state. For this reason, the characteristics are checked while hot, and accurate characteristics cannot be checked, and the work environment also becomes a problem.

As described above, there are the following problems.

First, since the characteristics of the ballast are deviated by heating the ballast, a characteristic test was required before and after the heating.

Second, by heating the ballast, the viscosity of the adhesive decreases, and in particular, the adhesive that has entered the air gap hangs down, and a part without the adhesive is formed. May cause noise.

Third, since there are time and line lengths for heating, warming and cooling, the ballast is not completely cooled, and the final inspection of the product in a hot state does not provide accurate characteristics.

Fourth, a general epoxy-based cold-setting adhesive is cured at normal temperature, and therefore has a Galan transition point (hereinafter referred to as “T”).
g value) was low and there was a problem in heat resistance. For this reason, there has been a problem that groaning occurs due to the early deterioration of the adhesive.

Fifth, since the adhesive is poured into the air gap portion by using an adhesive injecting jig, the adhesive flowing from the adhesive flow path, as shown in FIG. It may flow into a small gap formed between the upper surface of the laminated core and the tip surface of the adhesive injection jig, and the tip surface of the adhesive injection jig may become dirty.

At this time, since it is necessary to clean dirt on the tip surface of the adhesive injection jig, it is troublesome. Also, the adhesive flow path of the adhesive injection jig may be unusable due to the hardened adhesive.

[0030] The present invention has been made in view of the above points, and it is an object of the present invention to provide an electromagnetic device which has solved the problem caused by heating and curing an adhesive.

[0031]

According to a first aspect of the present invention, there is provided an electromagnetic apparatus using an adhesive in a joint or an air gap of a laminated iron core according to the present invention. The adhesive is characterized in that a two-stage curing adhesive that cures at two stages of room temperature and heating is used, and the heating is performed by self-heating during actual use.

According to the second aspect of the present invention, there is provided an electromagnetic device comprising:
The air gap portion is formed between a center leg laminated core and a side leg laminated core attached to a coil formed by winding an electric wire around a bobbin, and an adhesive is injected into the bobbin into the air gap portion. An injection guide in which a flow path is formed is formed as a body.

According to the third aspect of the present invention, there is provided an electromagnetic device comprising:
An epoxy resin / amine curing two-stage curing adhesive is used as the two-stage curing adhesive. In the above configuration, by using a (room temperature curing + heat curing) type two-stage curing adhesive without using a heat curing type adhesive, the adhesive is cured at room temperature during product assembly. . Further, heat curing progresses due to self-heating during actual use, leading to final curing, so that the cause of characteristic deviation and noise due to the dripping of the adhesive can be eliminated.

[0034]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A ballast as an electromagnetic device according to an embodiment of the present invention will be described below with reference to FIGS. Note that the same parts as in the prior art will be described with the same reference numerals.

FIG. 7 illustrates the steps of a production line for a glow start type 40 W transformer type fluorescent lamp ballast. 1 to 4 show the configuration of a transformer.
Is a P coil 10 and an S coil 20 as shown in FIG.
And a fitting hole 12 between the P coil 10 and the S coil 20.
I-shaped central leg laminated iron core 2 fitted into each
5 and a substantially square-shaped side leg laminated core 30 into which the central leg laminated core 25 fitted into the P coil and the S coil is press-fitted.
It is composed of

As a first step, a P coil and an S coil are assembled.

The P coil 10 has a main bobbin 11 having a rectangular fitting hole 12 into which the center leg laminated iron core 25 is press-fitted along the center line and an electric wire winding portion 13 around which the electric wire 8 is wound.
And the electric wire 8 wound around the electric wire winding portion 13 of the main bobbin 11. A terminal block 14 is formed at one end of the main bobbin, and terminals 9 and 9 are attached to the terminal block.

The S-coil 20 has an auxiliary bobbin 2 having a rectangular fitting hole 12 into which the center leg laminated iron core 25 is press-fitted along the center line and an electric wire winding portion 13 around which the electric wire 8 is wound.
1 and an electric wire 8 wound around the electric wire winding portion 13 of the auxiliary bobbin. A terminal block 14 is formed on the other end of the auxiliary bobbin, and terminals 9 are attached to the terminal block.

In the upper right half of the inner flange portion 13a of the main bobbin 11 or the auxiliary bobbin 21, as shown in FIG.
An adhesive injection guide 50 is integrally formed, and the adhesive injection guide 50 has an injection machine tip insertion concave portion 51 at a position of a distance L from the side edge 12a of the fitting hole 12 and as shown in FIG. A column-shaped adhesive flow path 52 having an adhesive outlet 53 at its lower end is provided in communication with the bottom of the injector insertion recess 51.

The adhesive injection guide 50 extends in the longitudinal direction from the outer surface of the inner flange portion 13a by a distance D, and the lower surface 54 of the adhesive injection guide is in contact with the upper edge 12b of the fitting hole 12. They are formed on the same plane.

As shown in FIG. 4, an air gap portion 40 is formed between the tip of the path portion 28 of the center leg laminated core and the tip of the path portion 34 of the side leg laminated core. An adhesive flow path 52 of an adhesive injection guide provided on the inner flange portion 13a of the bobbin 11 or 21 is formed on the upper side.

Further, the side opening 4 of the air gap 40 is provided.
0a and 40a are a pair of opposed inner flange portions 13
a, 13a. Further, the lower surface 54 of the adhesive injection guide is in contact with or close to the upper surfaces of the path portion 28 of the center leg laminated core and the path portion 34 of the side leg laminated core so as to close the air gap portion 40. Is formed.

As a first step, the electric wire 8 is attached to the main bobbin 11.
To form a P coil 10 and an S coil 20 in which the electric wire 8 is wound around the auxiliary bobbin 21.

As a second step, the fitting holes 1 formed on the respective center lines of the P coil 10 and the S coil 20
The center leg laminated iron cores 25 are fitted into the cores 2 and 12 and assembled. Then, the lead wire (not shown) of the P coil and the lead wire (not shown) of the S coil are connected to the terminals 9, respectively.

As a third step, the joint portion P
Arc-shaped convex portions 27 formed at both ends of the center leg iron core 25 combined with the coil and the S coil, and arc-shaped concave portions 32 formed at the inner side surfaces of both ends of the side leg laminated core 30 having a substantially rectangular shape.
In order to join the central leg iron core,
After applying a two-stage curing adhesive that cures at two stages of room temperature and heating to the arc-shaped concave portion 32 of the side leg laminated core 7 and the arcuate convex portions 27, 27 of the central leg laminated core, respectively. Arcuate concave portions 32 formed on inner surfaces of both ends of the core,
After the positioning, the transformer 5 is assembled by press-fitting.

At the time of press-fitting, since the guide portion 18 provided on the bobbin is pushed as shown in FIG. 1, the upper surface of the guide portion is horizontal so as to withstand the pressure at the time of press-fitting. The contact area is sufficient.

As the two-stage curing adhesive, for example, an epoxy resin / amine curing system two-stage curing adhesive is used.

In a state where the center leg laminated core 25 is pressed into the side leg laminated core 30, as shown in FIG. 4, the tip of the side leg laminated core path portion 34 and the central leg laminated core path portion 28 are formed.
An air gap portion 40 is formed between them.

As a fourth step, an adhesive is injected into the air gap of the transformer.

At the time of the injection of the adhesive, the state of the transformer 5
An epoxy-based two-stage curing adhesive is applied from above the adhesive injection guides 50 and 50 provided on the bobbin in the air gap portions on both sides formed by the path portion 34 of the left and right leg laminated cores and the path portion 28 of the central leg laminated core. A certain epoxy resin / amine curing system 2
Inject the step curing adhesive.

A method of injecting an adhesive into a pair of air gaps will be described with reference to FIGS.

After inserting and setting the tip of the adhesive injecting machine 57 into a pair of injecting machine inserting recesses 51, 51 provided on both sides of the transformer, the adhesive 70 is supplied from the injecting machine 57 to the air gap section 40, 51. The adhesive is filled in the air gap portion by feeding into the air gap 40.

As a fifth step, the ballast is assembled as shown in FIG.

First, the transformer 5 is attached to the bottom plate 2 by a method not shown, and the case is screwed and fixed to the bottom plate 2 with the screws 7 while the end plate covers 4 and 4 are arranged at both ends of the case 3. At the same time, the bottom plate 2 is crimped to the end plate covers 4 and 4.

As a sixth step, after performing a final characteristic inspection, a nameplate (not shown) is attached to the lower surface of the bottom plate 2, and then a final packing is performed.

That is, all steps from the heating step in the first-stage normal-temperature curing to the step before the nameplate is attached can be omitted, and any problems that may occur during the step can be eliminated. That is, the steps of the pre-heating inspection, the induction heating furnace, and the heat retaining furnace can be omitted.

Finally, as a second stage, in actual use, depending on the temperature of the ballast itself when the lamp is turned on, final curing is performed.
Strength and heat resistance, which are the inherent performance of the adhesive, can be obtained.

The operation of the ballast according to the above embodiment will be described.

As an adhesive bonding the joints 27 and 32 of the transformer as the electromagnetic device according to the present invention, or an adhesive injected into the air gap 40 to suppress vibration and noise generated from the air gap. As
Uses a two-stage curing adhesive that cures in two stages: normal temperature and heating, which are heated and cured by self-heating during actual use, without using a heat-curable adhesive. There is no need to heat the ballast, and there is no need for a line for heating, heat retention and cooling, so that the line can be shortened and the number of personnel can be reduced.

Further, since a heating step is not required at the time of assembling the product, there is no deviation in characteristics due to heating, the number of inspection steps before and after heating is reduced to one, and deviations in characteristics and noise due to dripping of the adhesive are eliminated. Can be eliminated.

Also, dripping of the adhesive due to heating is eliminated, the dirt on the line is reduced, and maintenance work is not required, so that labor can be saved.

Further, since the room-temperature curing type adhesive has a relatively wide selection range of the curing time as compared with the heat curing, an adhesive having a curing time suitable for the production line can be selected. It is also effective for work environment and energy saving.

After that, the epoxy two-stage curing adhesive is heated and cured by self-heating during actual use, and finally reaches the final curing. At this time, by heating, the Tg value is increased and the heat resistance is also improved, so that there is no early deterioration of the adhesive and the problem of growl is reduced.

The pair of air gaps formed on both sides of the transformer are formed inside the outer surface of the inner flange, so that the path 28 of the center leg laminated core and the path 34 of the side leg laminated core are formed. Even if the adhesive leaks from the gap formed between the upper surface and the lower surface of the adhesive injection guide, it does not protrude outside the inner flange portion.

This is because, when the adhesive is injected, both end surfaces of the adhesive injection guide and the outer wall of the inner flange portion are formed to abut against each other. This is because it is prevented from protruding from the part. This also has the effect of allowing the adhesive to smoothly enter the air gap.

[0066]

As described above in detail, according to the present invention, the following effects can be obtained in an electromagnetic device.

First, since a heating step is not required,
Line shortening and personnel reduction can be achieved. Further, there is no characteristic deviation due to heating, and the number of inspection steps before and after heating is reduced to one. In addition, the adhesive does not drip due to the heating, so that the stain on the line is reduced, and the labor for maintenance work can be saved.

Second, since the room temperature curing type adhesive has a relatively wide selection range of curing time as compared with the heat curing type adhesive, it is possible to select an adhesive having a curing time suitable for the production line. is there.

Third, energy saving and improvement of the working environment can be achieved.

Fourth, Tg which is a problem with the room temperature curing adhesive
As the value increases and the heat resistance improves, the problem of groaning can be reduced without early deterioration of the adhesive.

According to the second aspect, when the adhesive is injected into the air gap portion, the injection guide is provided not on the tip of the coating machine but on the bobbin so as to contact the center leg laminated core and the side leg laminated core. The surface is the lower surface of the adhesive injection guide provided on the inner flange portion of the bobbin. Even if the adhesive adheres to the lower surface of the center leg laminated core or the side leg laminated core and the lower surface of the adhesive injection guide, the surface becomes dirty. Is invisible,
No problem. Further, there is no problem even when the adhesive hardens in the adhesive flow path.

[Brief description of the drawings]

FIG. 1 is an exploded perspective view showing a configuration of a transformer main body according to a first embodiment of the present invention.

FIG. 2 shows a configuration of a bobbin in the first embodiment, and FIG. 2 (A) is a top view. (B) is a side view. (C)
Is a front view.

FIG. 3 is a sectional view showing an adhesive injection guide of the bobbin in the first embodiment.

FIG. 4 is a top view, partially in section, showing the configuration of the transformer main body according to the first embodiment.

FIG. 5 is a perspective view showing a state in which an adhesive is injected into the transformer main body in the first embodiment.

FIG. 6 is a sectional view showing a state where the transformer body is injected using an adhesive injection machine in the first embodiment.

FIG. 7 shows a glow start type 4 in the first embodiment.
FIG. 4 is a process chart showing the steps of a production line for a 0W transformer type fluorescent lamp ballast.

FIG. 8 is a perspective view showing a general transformer.

FIG. 9 is an exploded perspective view showing a configuration of a transformer main body according to the related art.

FIG. 10 is a perspective view showing an air gap section of a transformer body according to the related art.

FIG. 11 is a perspective view showing a state in which an adhesive is injected into the transformer body according to the related art using an adhesive injection jig.

FIG. 12 is a cross-sectional view showing a state in which an adhesive is injected into the transformer body according to the related art using an adhesive injection jig.

FIG. 13 shows a glow start type 40W according to the related art.
The process figure which shows the process of the production line of a transformer type fluorescent light ballast.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 11 ... Main bobbin (bobbin), 21 ... Auxiliary bobbin (bobbin), 25 ... Center leg laminated core (Laminated core), 30 ... Side leg laminated core (Laminated core), 40 ... Air gap part, 50 ... Adhesive injection guide (Injection guide), 70 ... adhesive.

Claims (3)

[Claims] 1. An electromagnetic device using an adhesive for a joint portion or an air gap portion of a laminated iron core, wherein the adhesive is a two-stage curing adhesive that cures at two stages of room temperature and heating, and the heating is performed. An electromagnetic device characterized by self-heating during use. 2. The air gap portion is formed between a center leg laminated core and a side leg laminated core attached to a coil formed by winding an electric wire around a bobbin. 2. The electromagnetic device according to claim 1, wherein an injection guide having a flow path for injecting the adhesive is formed. 3. The epoxy resin / epoxy resin according to claim 2, wherein
The electromagnetic device according to claim 1 or 2, wherein an amine-curing two-stage curing adhesive is used.