JP2000068147A - Resin mold coil - Google Patents

Abstract

PROBLEM TO BE SOLVED: To perform winding without the layer-down of a coil conductor without the need of many kinds of spacers respectively dedicated to the coil conductors of various different diameters, and to cope with the coil conductor of the diameter of further different special specifications. SOLUTION: The spacer 58 provided with an elastic body 57 in a piled-up state is arranged at the corner part of a winding frame 54 serving also as an inner die in a square cylindrical shape by turning the elastic body 57 to an outer side, the coil conductor 61 of a first layer is wound on the outer side, the coil conductors 61 of second and succeeding layers are successively wound on the outer side further, and thereafter sealing is performed by resin mold. In this case, the elastic body 57 provided on the spacer 58 is recessed as the outer shape of the coil conductor 61 by the tension of the winding of the coil conductor 61 of the first layer, the horizontal deviation of the coil conductor of the first layer by the tension at the time of winding the coil conductor 61 of the second layer is obstructed by the recess, and the layer-down of the coil conductor 61 of the second layer is prevented.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin mold coil having a structure in which a winding frame for winding a coil conductor also serves as an inner mold for resin molding.

[0002]

2. Description of the Related Art When manufacturing a molded coil such as a molded transformer or a molded reactor, as a method of resin-molding the electromagnetic coil, a coil is separately wound, and then the periphery of the coil is formed into an inner mold or an outer mold. In addition to the method of assembling with a mold and then injecting the resin into it and curing it, use the inner mold as a winding frame when winding the coil, remove it from the winding shaft after winding, attach the outer mold, and attach the resin There is a method of injecting and curing, a so-called straight winding method. The present invention relates to the latter series winding method, and as a conventional example thereof, FIG. 10 shows a partial cross section of a coil disclosed in Japanese Patent Publication No. 6-90983.

In FIG. 10, a coil inner circumferential insulating member 2 is wound around the outer side (upper side in the figure) of a bobbin (inner die) 1 and a coil conductor 3 is wound around the outside thereof in multiple layers. in this case,
The first-layer coil conductor 3 is wound in the order of 1, 2, 3,...
, And a second layer of coil conductor 3 is further wound outside from the right end to the left end in the order of 21, 22, 23..., And an interlayer insulator 4 is wound outside the coil conductor 3. Then, the coil conductor 3 and the interlayer insulator 4
Is repeated alternately.

In FIG. 10, the coil conductor 3 and the interlayer insulator 4 are divided into two (left and right in the figure) coil blocks and wound to form an electromagnetic coil 5 for one phase. . Then, after winding the coil, the winding frame 1 is removed from a winding shaft (not shown). Instead, an outer die (not shown) is attached, and then the resin 6 is injected and cured, and then the outer die is removed. Get 7.

According to this method, it is necessary to wind the interlayer insulator 4 for each layer of the coil conductor 3, and it is difficult to perform automatic winding. The interlayer insulator 4 is usually made of a plastic material such as an aromatic aramid or a polyester film.
Due to the difference in the coefficient of linear expansion, stress concentrates on the protruding end portion of the interlayer insulator 4, and the resin 6 peels off from the protruding portion, forming a notch, and there is a risk of developing a crack. For this reason, it is desirable to prevent the interlayer insulator 4 from traveling as far as possible from the coil conductor 3, and it is desirable to eliminate the interlayer insulator 4 if possible.

[0006] For example, Japanese Patent Application Laid-Open No. Hei 4-246611
FIG. 11 and FIG. In this embodiment, a core 11 having flanges 11a and 11b at both ends is provided.
Is used as a bobbin, and both collars 11a, 1 of the core 11 are used.
The coil conductor 12 is wound so as to fit between 1b.
Although the coil conductor 12 is wire-insulated by enamel coating or the like, it is wound obliquely as shown by an arrow so that multiple windings can be made without using an interlayer insulator.

A voltage corresponding to the order difference of the turns of the coil conductor is applied between the layers of the electromagnetic coil. According to the above, the order difference of the turns of the coil conductor is small (in the example of FIG. 11, Since the difference between the first turn and the tenth turn is a maximum of nine turns), the voltage applied between the layers of the electromagnetic coil is smaller than that of the example shown in FIG.
/ 4 to 1/20). Therefore, an interlayer insulator can be made unnecessary, and automatic winding becomes possible, and there is an advantage that there is no possibility that a crack of the resin may be caused by a protruding end of the interlayer insulator.

However, according to this configuration, the core 1
The dimension A between the two flanges 11a and 11b and the coil conductor 12
(A−n) from the value (a × n) obtained by multiplying the diameter “a” of one layer by the number of turns n for one layer has a subtle effect. In particular, if the dimension A is too large, the coil conductor of the second layer 12 pushes the coil conductor 12 of the first layer in the lateral direction by the tension, and FIG.
Then, a step is dropped like a coil conductor indicated by 12a. In particular, when the diameter a of the coil conductor 12 is 2 [mm] or less,
It is very difficult to perform the close contact winding as shown in FIG. 11, and there is a disadvantage that a monitoring operation for correcting the above-mentioned step drop during winding is required.

As a solution to this drawback, the present applicant has considered what is shown in FIGS. In this case, as shown in FIG. 13, spacers 22 are arranged at respective corners of a winding frame 21 having a rectangular tubular shape. As shown in FIG. 14, the spacer 22 has a large number of grooves 23 arranged in parallel, and the pitch P of the grooves 23 is as shown in FIG.
5 is substantially equal to the diameter of the coil conductor 24 shown in FIG. 5, the coil conductor 24 is arranged along each of the grooves 23, and the coil conductor 24 is placed on the bobbin 21 in FIG.
3, and the number of turns required (9 in the figure)
To 0).

In this case, the coil conductors 24 of the second and subsequent layers are wound along the valleys of the coil conductors 24 of the preceding layer, and the lower and upper layers are successively stacked in a bale stack, while the voltage between the layers is minimized. It is wound by inclined winding so that it becomes. In addition, no interlayer insulator is arranged between the respective layers,
The insulation between the coil conductors 24 relies solely on the insulation of the coil conductors 24 by enamel coating.

Thus, the coil coil 24 is wound up to the outermost periphery to form the electromagnetic coil 25. Thereafter, the winding frame 21 is removed from the end plate 27 previously held on the winding shaft 26, and as shown in FIG. The lead wire 28 is connected to the lead-out terminal 29, and the upper die 30, the lower die 31,
And an outer mold 33 composed of a peripheral mold 32. After this,
A predetermined drying process is performed, and thereafter, the reel 21 and the outer mold 33 are formed.
Between the injection port 34 of the upper mold 30 and the resin 35.
And heat-cured. Therefore, the winding frame 21 also serves as an inner mold, and when the resin 35 is cured, the outer mold 33 is removed to obtain a resin mold coil.

According to this structure, the position of the coil conductor 24 is fixed by the groove 23 of the grooved spacer 27 at the same time as the winding on the winding frame 21, and the first layer is wound.
The first layer is wound along each valley of the coil conductor 24 of the first layer. At this time, the coil conductor 24 of the second layer tries to push away the coil conductor 24 of the first layer by the tension in the lateral direction.
The groove 23 stops the coil conductor 24 of the first layer. Thus, the lateral displacement of the first-layer coil conductor 24 is eliminated, and the step-down of the second-layer coil conductor 24 is prevented.

Therefore, the diameter d of the coil conductor 24 is 2 [m
m] or less, the coil conductor 24 does not need to be monitored to correct a step drop like the conventional one.
Can be wound normally, and productivity can be improved.

[0014]

However, the diameter of the coil conductor 24 varies depending on the capacity of the transformer or the reactor.
Various types of spacers having grooves 23 having a pitch corresponding to each diameter of the coil conductor 24 are required, and various types of dies are required to manufacture the spacers, and parts management becomes complicated. In addition, even if various types of spacers are prepared, the types that can be prepared are limited, and other types of spacers having different diameters of the coil conductor 24 cannot be supported. Having.

[0015] The present invention has been made in view of the above-mentioned circumstances, and an object of the present invention is to provide a multi-type winding having a coil conductor with no step-down, which has various diameters of the coil conductor. Another object of the present invention is to provide a resin molded coil which can be formed without the need for the spacer and which can cope with a special specification having a further different coil conductor diameter.

[0016]

Means for Solving the Problems In order to achieve the above object, a resin molded coil of the present invention comprises, first, a winding frame which also serves as a rectangular cylindrical inner mold. A spacer having an elastic body in a superimposed state is arranged with the elastic body on the outside, the coil conductor of the first layer is wound on the outside, and the coil conductors of the second and subsequent layers are successively wound on the outside. An electromagnetic coil is formed, and the electromagnetic coil is sealed with a resin mold.

According to this structure, the elastic body of the spacer is depressed according to the outer shape of the coil conductor due to the tension of the winding of the coil conductor of the first layer. When the coil conductor of the second layer is wound, the coil conductor of the second layer tries to push the coil conductor of the first layer in the lateral direction by its tension. The coil conductor of the first layer in which the body is recessed is stopped by the recess of the elastic body, and the lateral displacement is eliminated. Thus, the step-down of the coil conductor of the second layer is prevented.
Regarding various types of coil conductors having different diameters, the elastic body is depressed according to each outer shape of the coil conductor to prevent the stepping of the second-layer coil conductor.

Further, the spacer having the elastic body is arranged at the corner of the winding frame having a rectangular cylindrical shape, so that the tension of the coil conductor is higher than the flat portion between the corners. Accordingly, not only is the degree of fixing of the spacer pressed down high, but also the dent of the elastic body due to the coil conductor can be made more reliably, so that the effect of preventing the coil conductor from stepping down can be obtained more reliably. be able to.

Secondly, the resin molded coil of the present invention comprises:
It is provided with a bobbin serving also as a rectangular cylindrical inner mold, and a spacer having an adhesive elastic body in an overlapping state is arranged at a corner portion of the bobbin with the elastic body outside, and one layer outside the spacer. It is characterized in that an electromagnetic coil is formed by winding a coil conductor of the first order, and further winding the coil conductors of the second and subsequent layers on the outside thereof, and sealing the electromagnetic coil with a resin mold.

According to this structure, the elastic body has an adhesive property due to the depression of the elastic body due to the tension of the winding of the coil conductor, whereby the first layer is pressed against the pushing force of the second layer by the coil conductor. The step of the coil conductor of the second layer can be more reliably prevented because the coil conductor of the second layer is more securely stopped. The adhesiveness of the elastic body is also effective for various types of coil conductors having different diameters. The elastic body adheres to the coil conductors regardless of the diameter of the coil conductors, thereby preventing step-down.

Third, the resin-molded coil of the present invention comprises:
It has a winding frame that also serves as an inner shape of a rectangular tube, and a spacer having an adhesive sheet in an overlapping state is arranged at a corner of the winding frame with the adhesive sheet outside, and a coil of the first layer is placed outside the spacer. The present invention is characterized in that an electromagnetic coil is formed by winding a conductor and sequentially winding the coil conductors of the second and subsequent layers on the outside thereof, and the electromagnetic coil is sealed with a resin mold.

According to this structure, the first-layer coil conductor is stopped against the pushing force of the second-layer coil conductor due to the adhesiveness of the pressure-sensitive adhesive sheet. It can be reliably prevented. Also in this case, the adhesiveness of the pressure-sensitive adhesive sheet is effective for various types of coil conductors having different diameters, and prevents the stepping by adhering the coil conductors regardless of the diameter of the coil conductors.

Fourth, the resin molded coil according to the present invention comprises:
A winding frame that also serves as an inner shape of a rectangular tube is provided. An adhesive sheet is directly disposed at a corner of the winding frame, a first-layer coil conductor is wound around the outside thereof, and a second-layer coil conductor is further outside the winding. The subsequent coil conductors are sequentially wound to form an electromagnetic coil, and the electromagnetic coil is sealed with a resin mold.

According to this structure, the first-layer coil conductor is stopped against the pushing force of the second-layer coil conductor due to the adhesiveness of the pressure-sensitive adhesive sheet. Can be prevented. Further, even in this case, the adhesiveness of the pressure-sensitive adhesive sheet is effective for various types of coil conductors having different diameters, and the step of preventing the stepping is prevented by adhering the coil conductor regardless of the diameter of the coil conductor.

[0025]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a first embodiment of the present invention will be described with reference to FIGS. First, FIG. 1 shows a winding shaft 51, and end plates 52 are attached to both left and right ends in the drawing. Each of the end plates 52 has a convex portion 53 on an inner surface portion in the axial direction (left and right in the drawing), and a winding frame 54 is fitted on these radially outer surface portions (upper side in the drawing). The winding frame 54 also serves as an inner mold, and is a two-part type joined by two core molds 55 as shown in FIG. It is fitted from the outside, and is then separably connected by a core mold 55.

The winding frame 54 in the connected state has a rectangular cylindrical shape, and a flat chamfered portion 56 is formed at each of its four corners. In this case, the winding frame 54
The chamfered portion 56 is formed by forming the winding frame 54 into an octagon as a whole having short sides also at the corners.

In the chamfered portion 56 of the winding frame 54, spacers 58 each having an elastic body 57 are arranged. As shown in detail in FIG. 3, the spacer 58 is formed of a strip-shaped insulating plate, and has a width W substantially equal to the circumferential length of the chamfered portion 56 of the winding frame 54. The length L is set substantially equal to the width (length in the axial direction) of the winding frame 54, and the thickness t including the elastic body 57 is set to a dimension corresponding to the required thickness of the inner peripheral insulating layer of the resin molded coil after completion. And

In addition, the spacer 58 is formed of, for example, the same resin as a molding resin described later, and its surface is subjected to surface roughening treatment by, for example, sandblasting. On the other hand, the elastic body 57 is made of a material having heat resistance equivalent to that of the molding resin, for example, silicone rubber, and is integrated with the spacer 58 in an overlapping state.

With this configuration, as shown in FIG.
7 to the outside, and the spacer 58 in this state is
A concave portion 59 formed in a portion radially outside of the second convex portion 53
Then, it is inserted together with both ends of the elastic body 57, and is pressed down from above with a holding metal fitting 60 and fixed together with the winding frame 54. The elastic body 57 is fixedly arranged with the outside facing outward.

Thereafter, a coil conductor 61 made of, for example, an enamel-coated conductor is placed on the outside of the elastic body 57 in FIG.
3, and the number of turns required (9 in the figure)
To 0). In this case, the coil conductors 61 of the second and subsequent layers are wound along the valleys of the coil conductors 61 of the preceding layer,
From the lower layer to the upper layer, while sequentially stacking in a bale stack,
It is wound by inclined winding so that the voltage between layers is minimized. The number m of winding steps is set to 5, no interlayer insulator is provided between the layers, and insulation between the coil conductors 61 depends solely on insulation of the coil conductors 61 by enamel coating.

Thus, the electromagnetic coil 62 is formed by winding the coil conductor 61 to the outermost periphery.
2 is removed from the end plate 52 (winding shaft 51), and as shown in FIG. 4, the lead wire 63 is connected to the lead-out terminal 64, and the upper frame 65 and the lower die 66 , And an outer mold 68 including a peripheral mold 67.

Thereafter, a predetermined drying process is performed, and thereafter, the reel (inner die) 5 is fed through the injection port 69 of the upper die 65.
An epoxy resin 70, which is a resin for molding, is injected between the outer mold 4 and the outer mold 68, and is cured by heating. At this time, the elastic body 5 between the winding frame 54 and the first layer of the coil conductor 61 is formed.
The epoxy resin 70 also reaches the gap 71 (see FIG. 2) secured by the spacer 58 having the 7, so that an appropriate inner peripheral insulating layer can be obtained. Then, when the epoxy resin 70 has hardened, the outer mold 68 is removed to obtain a resin mold coil.

Now, in the case of the configuration as described above,
When the first-layer coil conductor 61 is wound, the spacer 5
As shown in FIG. 1, the elastic body 57 included in 8 is recessed according to the outer shape of the coil conductor 61 due to the tension of the winding of the coil conductor 61 of the first layer. When the coil conductor 61 of the second layer is wound, the coil conductor 61 of the second layer tries to push the coil conductor 61 of the first layer in the lateral direction by the tension. The above-mentioned elastic body 57
The coil conductor 61 of the first layer in which the elastic body 57
And the lateral displacement is prevented, and thus the step of the second-layer coil conductor 61 is prevented.

Therefore, in this case, the coil conductor 61
Even if the diameter d of the coil conductor 61 is equal to or less than 2 [mm], the coil conductor 61 can be normally wound without monitoring work for correcting a step drop unlike a conventional one, and productivity can be improved. Can be.

Further, in this case, the elastic body 57 is also formed to be concave according to each outer shape of the coil conductor to prevent the coil conductor of the second layer from dropping, even if the coil conductor has various diameters. And therefore the spacer 22 described above.
Unlike the idea of preventing the stepping of the coil conductor 24 by the groove 23 formed in the groove, even if the diameter of the coil conductor changes for each capacity of the transformer and the reactor, the groove of the dedicated pitch corresponding to each diameter of the coil conductor Is not required.

Accordingly, there is no need to use various types of molds for manufacturing various types of spacers, and there is no need for complicated parts management. In addition, the elastic body 57 may be used for special specifications in which the diameter of the coil conductor is further different.
Is, again, recessed as per the outline of the coil conductor,
This prevents stepping down of the coil conductor of the second layer, and therefore can sufficiently cope with that.

The spacer 5 having the above-mentioned elastic body 57
In FIG. 8, since the coil conductor 61 is disposed at the corner of the rectangular cylindrical winding frame 54, the tension of the coil conductor 61 is higher than the flat portion between the corners. In addition to obtaining a high degree of attachment and fixing, the depression of the elastic body 57 by the coil conductor 61 is more reliably performed, so that the effect of preventing the coil conductor 61 from dropping down can be more reliably obtained.

Further, since the winding frame 54 has a flat chamfered portion 56 at a corner portion and the spacer 58 is disposed on the chamfered portion 56, the spacer 58 can be easily set and the coil conductor 61 Spacer 5 when winding
8 can be reliably fixed without being displaced by being pulled in the winding direction. In addition, following the coil conductor 61 of the first layer wound around the outside of the elastic body 57, the coil conductors 61 of the second and subsequent layers are wound along the valleys of the coil conductor 61 of the previous layer. Space factor can be improved, and the overall size and weight can be reduced.

Further, since the coil conductors 61 are sequentially stacked in a bale stack from the lower layer to the upper layer and wound, the winding frame 54 needs to have a flange 11a, 11b at both ends like the conventional core 11. Multi-stage stacking is possible at least, and accordingly, the entire axial direction can be reduced in size and the weight can be reduced. Further, since the spacer 58 is formed of the same resin as the molding resin 70 and the surface thereof is roughened, the spacer 58
It can be integrated well with 0 to further improve crack resistance.

5 to 9 show the second to sixth embodiments of the present invention. The description of the same parts as in the first embodiment will be omitted, and only different parts will be described. .

[Second Embodiment] In the second embodiment shown in FIG. 5, an adhesive elastic body 81 is provided in an overlapping state instead of the spacer 58 having the simple elastic body 57 in the overlapping state. A spacer 58 is used, and this is disposed on the chamfered portion 56 of the winding frame 54 with the adhesive elastic body 81 outside, and the coil conductor 61 of the first layer is wound around the outside. In this case, the sticky elastic body 81 is
It is made of a material having heat resistance equivalent to that of a molding resin and having tackiness at room temperature, for example, silicone gel.

According to this, the aforementioned coil conductor 61
The elasticity of the elastic body 81 is added to the recess of the elastic body 81 due to the tension of the winding of the above, so that the stopping of the coil conductor 61 of the first layer against the pushing force of the coil conductor 61 of the second layer can be more reliably performed. Therefore, the step-down of the coil conductor 61 of the second layer can be more reliably prevented.

In this case, even if the coil conductor 61 has various diameters, the elastic body 81 is depressed in accordance with the outer shape of the coil conductor 61 and the coil conductor 61 is formed irrespective of the diameter of the coil conductor 61. Stick the conductor 61,
As described above, even if the diameter of the coil conductor 61 changes according to the capacity of the transformer or the reactor, various types of spacers having grooves with a dedicated pitch corresponding to each diameter of the coil conductor 61 are used, as described above. It is not necessary, and it is possible to sufficiently cope with a special specification having a further different diameter of the coil conductor.

[Third Embodiment] In the third embodiment shown in FIG. 6, instead of the spacer 58 having the adhesive elastic body 81 in the overlapping state, the spacer having the adhesive sheet 91 in the overlapping state is used. An adhesive sheet 91 is disposed on the chamfered portion 56 of the winding frame 54 with the adhesive sheet 91 outside, and the coil conductor 61 of the first layer is wound around the outside. In this case, the pressure-sensitive adhesive sheet 91 is, for example, a material obtained by applying a resin having heat resistance equivalent to that of a molding resin to a material obtained by knitting glass fiber into a net shape and making it semi-cured (epoxy resin prepreg glass net ) And has tackiness at room temperature.

According to this, the first-layer coil conductor 61 is stopped against the pushing force of the second-layer coil conductor 61 due to the adhesiveness of the adhesive sheet 91. Step can be reliably prevented.

In this case, even if the coil conductor 61 has various diameters, the pressure-sensitive adhesive sheet 91 adheres the coil conductor 61 regardless of the diameter of the coil conductor 61 to prevent a step drop. As described above, even if the diameter of the coil conductor 61 changes for each capacity of the transformer and the reactor, it is not necessary to use various kinds of spacers having grooves of a dedicated pitch corresponding to each diameter of the coil conductor 61. In addition, it is possible to sufficiently cope with special specifications having different diameters of coil conductors.

Further, in this case, since the base material of the pressure-sensitive adhesive sheet 91 is made of glass fiber and is present at the corner of the winding frame 54 where high thermal stress is generated, the reinforcement of the resin 70 is more effective. And the crack resistance can be improved.

[Fourth Embodiment] In the fourth embodiment shown in FIG. 7, an adhesive sheet 101 is used instead of the spacer 58 having the adhesive sheet 91 in the overlapping state, and this is used as a bobbin. The coil conductor 61 of the first layer is wound directly on the chamfered portion 54 and wound on the outside thereof. In this case, the pressure-sensitive adhesive sheet 101 is of the same quality as the pressure-sensitive adhesive sheet 91 described above.

Also in this case, the first-layer coil conductor 61 is stopped against the pushing force by the second-layer coil conductor 61 due to the adhesiveness of the adhesive sheet 101. Stepping can be reliably prevented.

In this case, even if the coil conductor 61 has various diameters, the pressure-sensitive adhesive sheet 101 adheres the coil conductor 61 regardless of the diameter of the coil conductor 61 to prevent a step-down. , As before,
Even if the diameter of the coil conductor 61 changes depending on the capacity of the transformer or the reactor, there is no need to use various kinds of spacers having grooves with a dedicated pitch corresponding to each diameter of the coil conductor 61, and the diameter of the coil conductor 61 However, it is possible to sufficiently cope with special specifications having different characteristics. in addition,
In this case, a spacer is not required for each of the pressure-sensitive adhesive sheets 101, and the step of superimposing the pressure-sensitive adhesive sheet 101 on the spacers and integrating them is not required.

Fifth Embodiment In the fifth embodiment shown in FIG. 8, a curved chamfer 111 is formed at the corner of the bobbin 54 in place of the flat chamfer 56 described above.
Like the spacer 58 having the elastic body 57 of the first embodiment, spacers 113 having the elastic bodies 112 in a superposed state are arranged at both ends thereof, and outside thereof,
The first layer coil conductor 61 is wound.

In this case, by increasing the radius of curvature of the chamfered portion 111 to make the degree of chamfering larger than that of the flat chamfered portion 56, the chamfered portion 111 is formed.
Is located inside the chamfered portion 56, the circumferential length of the coil conductor 61 to be wound can be shortened, and the amount of the coil conductor 61 and the amount of the molding resin 70 can be reduced. A lightweight and compact resin molded coil can be achieved. In addition, the curved chamfered portion 111 is also effective in relieving stress at a corner portion of the resin mold coil, and can improve crack resistance.

In this case, at each end of the chamfered portion 111, instead of the spacer 113 having the elastic body 112 described above, the same adhesive 58 as the spacer 58 having the adhesive elastic body 81 of the second embodiment is used. A spacer having an adhesive sheet in an overlapped state, like the spacer having an elastic elastic body in an overlapped state or the spacer 58 having the adhesive sheet 91 of the third embodiment, may be arranged.

[Sixth Embodiment] In the sixth embodiment shown in FIG. 9, the adhesive sheet 101 of the fourth embodiment is applied to the entire surface of the curved chamfered portion 111 formed at the corner of the winding frame 54 described above. Similar pressure-sensitive adhesive sheets 121 are arranged directly one by one, and a first-layer coil conductor 61 is wound around the outside thereof.

In this embodiment, in addition to the same operation and effect as described above, in particular, due to the flexibility of the adhesive sheet 121 alone, the adhesive sheets 121 can be arranged one by one along the curved surface of the chamfered portion 111. Spacer 113 of the fifth embodiment
It is not necessary to divide and arrange at both ends of the chamfered portion 111 as in the above, so that the number of parts used can be reduced.

In addition, the present invention is not limited to the embodiment described above and shown in the drawings. For example, a chamfer may not be formed at each corner of the bobbin. The coil conductors of the second and subsequent layers need not necessarily be wound along the valleys of the coil conductors of the preceding layer. Furthermore, the coil conductor does not necessarily need to be stacked and wound sequentially from the lower layer to the upper layer in a bale stack, and the spacer may be made of a resin different from the molding resin, and the surface roughening treatment is also required. is not.

[0057]

As described above, according to the present invention, not only can the coil conductor be wound without step dropping, but particularly, the winding without step drop of the coil conductor can be reduced by the diameter of the coil conductor. For different things,
By eliminating the need for various types of spacers, it is possible to reduce the number of molds used to manufacture the spacers, and also to facilitate component management. In addition, it is possible to cope with special specifications with different diameters of coil conductors, and it is possible to obtain a high degree of fixing of spacer pressing by coil conductor tension at the corner of the winding frame. Thereby, the effect of preventing the coil conductor from dropping can be more reliably obtained.

[Brief description of the drawings]

FIG. 1 is a sectional view showing a first embodiment of the present invention, taken along line BB of FIG. 2;

FIG. 2 is a longitudinal sectional view of a wound state of a coil conductor.

FIG. 3 is an enlarged perspective view of a single spacer having an elastic body.

FIG. 4 is a longitudinal sectional view of the electromagnetic coil in a state of resin molding.

FIG. 5 is a view corresponding to FIG. 1 showing a second embodiment of the present invention.

FIG. 6 is a view corresponding to FIG. 1 showing a third embodiment of the present invention.

FIG. 7 is a view corresponding to FIG. 1, showing a fourth embodiment of the present invention.

FIG. 8 is an enlarged view corresponding to FIG. 2 showing a fifth embodiment of the present invention.

FIG. 9 is a view corresponding to FIG. 8, showing a sixth embodiment of the present invention.

FIG. 10 is a longitudinal sectional view of a half part of a product showing a conventional example.

FIG. 11 is a diagram corresponding to FIG. 10 showing a different conventional example.

FIG. 12 is a diagram corresponding to FIG. 10 in a state where the disadvantages of the conventional example appear.

FIG. 13 is a diagram corresponding to FIG. 2 showing a further different conventional example.

FIG. 14 is a diagram corresponding to FIG. 3;

FIG. 15 is a cross-sectional view (corresponding to FIG. 1) along the line CC of FIG. 13;

FIG. 16 is a diagram corresponding to FIG. 4;

[Explanation of symbols]

54 is a winding frame, 57 is an elastic body, 58 is a spacer, 61 is a coil conductor, 62 is an electromagnetic coil, 70 is an epoxy resin (resin for molding), 81 is an adhesive elastic body, 91 and 10
1 is an adhesive sheet, 112 is an elastic body, 113 is a spacer,
Reference numeral 121 denotes an adhesive sheet.

Claims (4)

[Claims] 1. A winding frame which also serves as an inner shape of a rectangular tube, a spacer having an elastic body superposed on a corner portion of the winding frame is disposed with the elastic body being outside, and on the outside thereof,
A resin characterized in that an electromagnetic coil is formed by winding a coil conductor of the first layer, and further sequentially winding coil conductors of the second layer and thereafter on the outside thereof, and sealing the electromagnetic coil with a resin mold. Mold coil. 2. A winding frame which also serves as an inner shape of a rectangular tube, and a spacer having an adhesive elastic body superposed on a corner portion of the winding frame is disposed with the elastic body being on the outside. An electromagnetic coil is formed by winding a coil conductor of the first layer on the outside, and further winding coil conductors of the second and subsequent layers on the outside of the coil, and sealing the electromagnetic coil with a resin mold. Resin mold coil. 3. A winding frame which also serves as an inner shape of a rectangular cylinder, a spacer having an adhesive sheet in an overlapping state is arranged at a corner portion of the winding frame with the adhesive sheet outside, and on the outside thereof, A resin characterized in that an electromagnetic coil is formed by winding a coil conductor of the first layer, and further sequentially winding coil conductors of the second layer and thereafter on the outside thereof, and sealing the electromagnetic coil with a resin mold. Mold coil. 4. A winding frame which also serves as an inner shape of a rectangular tube, an adhesive sheet is directly disposed at a corner of the winding frame, and a first layer of coil conductor is wound around the outside thereof. 2 outside
A resin-molded coil characterized by forming an electromagnetic coil by sequentially winding coil conductors on and after the layer, and sealing the electromagnetic coil with a resin mold.