JP2001217129A - Molded coil - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve the efficiency of a disassembly of a base coil and to realize a molded coil, while giving consideration to the environment with enhancement of recyclability. SOLUTION: An inner peripheral material is formed into a laminated structure formed, by superposedly winding sheet materials 1 consisting of a woven textile of the quantity of a fiber born with a prepreg resin and sheet materials 2, consisting of an unwoven fabric of the quality of a fiber born with a prepreg resin and an outer peripheral material is also formed into a laminated structure, formed by superposedly winding sheet materials 5 consisting of a woven textile of the quality of a fiber born with a prepreg resin and sheet materials 6 consisting of an unwoven fabric of the quantity of a fiber born with a prepreg resin in the same way as the inner peripheral material. By forming the inner and outer peripheral materials into such a structure, the resin impregnability of a molded coil is enhanced, the thermal characteristics, mechanical characteristics and electrical insulating characteristics of the coil are enhanced, and the isotropy of the thermal and mechanical behaviors of the coil is enhanced. Moreover, since a firm resin layer does not exist on the peripheries of the inner and outer peripheral materials, the efficiency of a disassembly of the coil is enhanced, and a reutilizable coil conductor 3 can be recovered.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molded coil for electromagnetic equipment.

[0002]

2. Description of the Related Art Conventionally, a molded coil has been disclosed in
No. 737 and Japanese Patent Application Laid-Open No. 1-93107 are known. FIG. 4 is a partial schematic cross-sectional view showing the structure of the elementary coil of the conventional molded coil. FIG.
(A) shows a case where a sheet-shaped coil conductor is used, 41 is an insulating inner peripheral material, 42 is an impregnating member,
Reference numeral 3 denotes a sheet-like coil conductor, and reference numeral 44 denotes an interlayer insulating material.
FIG. 4B shows a case where a round wire is used for the coil conductor,
45 is an insulating inner peripheral material, 46 is an impregnating member, 47 is a round coil conductor, and 48 is an interlayer insulating material.

FIG. 5 is a partial schematic cross-sectional view showing the structure of a conventional molded coil. 49 is an insulating inner peripheral material, 50 is a porous insulating member excellent in resin impregnation, 51 is a coil conductor, 52 is a coil conductor. Is an interlayer insulating material, 53 is an insulating outer peripheral material, and 54 is a mold resin. The inner peripheral member 49 and the outer peripheral member 53 have a laminated structure of glass cloth supporting a resin, and the porous insulating member 50 is composed of glass cloth or glass paper. As shown in FIG. 5, the inner peripheral member 49 and the outer peripheral member 5
3 is filled with a mold resin 54 at the end of the elementary coil to form a molded coil. In FIG. 5,
Although a coil conductor 51 using a round wire similar to that shown in FIG. 4B is shown, the same configuration can be made when a sheet-like conductor as shown in FIG. 4A is used. However, this structure
The application is limited to an electromagnetic coil in a low voltage field, and when applied to a high voltage field, the configuration is as shown by a high voltage coil in FIG. 6 which is entirely molded with resin.

FIG. 6 is a partially cutaway schematic view of a transformer in which a conventional molded coil is incorporated in an iron core.
55 is an elementary coil constituting the high voltage coil 60, 56 is a low voltage coil, 57 and 58 are molding resin, and 59 is an electromagnetic iron core. Here, the high voltage coil 60 includes a plurality of element coils 55.
Are connected and housed in a mold, and filled with resin to form a molded coil.

[0005]

In such a molded coil for an electromagnetic device, not only a product but also a molded coil is used.
Although comprehensive environmental measures including the manufacturing process are required, the high-voltage coil 6 shown in FIG.
In the structure of No. 0, since the periphery is covered with the strong mold resin 57, the element coil for separating the conductor from the mold resin and other insulating materials is poorly degradable, and the recyclability which is an environmental evaluation index is poor. Was bad.

SUMMARY OF THE INVENTION It is an object of the present invention to provide an environment-friendly molded coil which can improve the resolvability of the elementary coil and improve the recyclability.

[0007]

SUMMARY OF THE INVENTION In order to solve this problem, the present invention provides an inner peripheral material and an outer peripheral material formed on a first sheet material in which a prepreg resin is supported on a fibrous fabric and a fibrous nonwoven fabric. A mold coil characterized in that a second sheet material carrying a prepreg resin is superposed and wound to form a composite laminated structure.

As a result, the decomposability of the element coil is improved, the recyclability, which is an index for evaluating the environment, is improved, and the insulation reliability of the molded coil is also increased.

The present invention is also directed to winding one of a first sheet material having a prepreg resin supported on a fibrous woven fabric and a second sheet material having a prepreg resin supported on a fibrous nonwoven fabric. A molded coil characterized in that it is turned to form an inner peripheral member, and the other sheet member is wound to form an outer peripheral member.

As a result, the decomposability of the element coil is improved, and the recyclability, which is an index for evaluating the environment, is improved.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION
On the outer periphery of the element coil in which the coil conductor and the interlayer insulating material are wound with a width smaller than the width of the inner peripheral material, an outer peripheral material having a width substantially equal to the inner peripheral material is provided. A mold coil in which both ends of an elementary coil are filled with mold resin, wherein an inner peripheral material and an outer peripheral material are a first sheet material in which a prepreg resin is supported on a fibrous woven fabric, and a prepreg is formed on a fibrous nonwoven fabric. A mold coil characterized in that a second sheet material carrying a resin is superimposed and wound to form a composite laminated structure. According to such a configuration, the base material of the inner peripheral material and the outer peripheral material is Since it is a composite structure of woven and non-woven fabrics, it has excellent electrical insulation and mechanical properties, increases the effective resin filling rate, improves thermal conductivity, and at the same time surrounds the inner and outer peripheral materials. Disassembly of elementary coil due to lack of strong resin layer But it improved, recycling is improved.

According to a second aspect of the present invention, there is provided a coil having a coil conductor and an interlayer insulating material wound around the inner peripheral member with a width smaller than the width of the inner peripheral member. Is a molded coil in which the both ends of the element coil between the inner peripheral material and the outer peripheral material are filled with a mold resin, and a first sheet material in which a prepreg resin is supported on a fibrous fabric; A second sheet material carrying a prepreg resin on a fibrous nonwoven fabric, and winding one of the sheet materials to form an inner peripheral material; and winding the other sheet material to form an outer peripheral material. With such a configuration, since there is no strong resin layer around the inner peripheral material and the outer peripheral material, the disassembly of the element coil is improved, and the recyclability is improved. In addition, since the inner peripheral member and the outer peripheral member are each composed of one type of sheet material, workability in manufacturing the molded coil is improved. In addition, in this configuration, since the direction in which the stress acts depends on the electromagnetic design of the coil, the insulating and thermal conductivity are excellent by using a sheet material made of a nonwoven fabric for the inner peripheral material or the outer peripheral material that does not apply much stress. The outer peripheral material or the inner peripheral material to which a large stress is applied is constituted by a sheet material made of a woven fabric having excellent mechanical properties.

According to a third aspect of the present invention, the inner peripheral member and the outer peripheral member are arranged such that a first sheet material having a prepreg resin supported on a fibrous fabric is disposed on each outer surface. 2. The molded coil according to claim 1, wherein the inner peripheral surface of the inner peripheral member and the outer peripheral surface of the outer peripheral member are made of a woven fabric as a base material. Since it is made of a material, the durability against damage during operation is high, the damage is reduced, and the withstand voltage at the interface with the mold resin is also improved.

The invention according to claim 4 of the present invention is characterized in that the fibrous woven fabric of the first sheet material is a glass fiber woven fabric, and the fibrous nonwoven fabric of the second sheet material is a glass fiber nonwoven fabric. The molded coil according to claim 1, 2 or 3, wherein the base material of the inner peripheral material and the outer peripheral material is made of glass fiber, so that the heat conductivity is excellent and the thermal expansion is further improved. Since the coefficient is a laminated structure of the glass fiber nonwoven fabric and the woven fabric, the base material is closer to the mold resin than the glass fiber woven fabric alone, and the change in the internal stress due to the temperature change is small.

The invention according to claim 5 of the present invention is characterized in that the fibrous woven fabric of the first sheet material is a glass fiber woven fabric, and the fibrous nonwoven fabric of the second sheet material is a polyester fiber nonwoven fabric. The molded coil according to claim 1, 2, or 3,
Since the base material of the inner peripheral material and the outer peripheral material is a glass fiber woven fabric and a polyester fiber non-woven fabric, the difference in thermal expansion coefficient between the resin and the resin is small, and the generation of thermal stress with respect to temperature change is small. Further, since the filling of the resin is improved, the electric insulation property, particularly the dielectric breakdown voltage is high, and the thermal conductivity is also improved.

According to a sixth aspect of the present invention, the fibrous woven fabric of the first sheet material is a glass fiber woven fabric, and the fibrous nonwoven fabric of the second sheet material is an aromatic polyamide fiber nonwoven fabric. The molded coil according to claim 1, wherein the base material of the inner peripheral material and the outer peripheral material is made of a glass fiber woven fabric and an aromatic polyamide fiber non-woven fabric. It has excellent heat resistance, a thermal expansion coefficient close to that of resin, and excellent mechanical properties due to the synergistic effect of the glass fiber woven fabric and the aromatic polyamide fiber non-woven fabric.

According to a seventh aspect of the present invention, the fibrous woven fabric of the first sheet material is a polyester fiber woven fabric,
4. The molded coil according to claim 1, wherein the fibrous non-woven fabric of the second sheet material is a polyester fiber non-woven fabric. The base material is made of polyester fiber, so the difference in thermal expansion coefficient with resin is small, and the combined use of woven fabric and non-woven fabric makes the base material superior in mechanical properties compared to non-woven fabric alone, and the base material is woven fabric alone As compared with the above, since the filling of the resin is improved, the thermal conductivity is also improved.

[0018] In the invention according to claim 8 of the present invention, the fibrous woven fabric of the first sheet material is a polyester fiber woven fabric,
The molded coil according to claim 1, 2 or 3, wherein the fibrous nonwoven fabric of the second sheet material is a glass fiber nonwoven fabric.
The mechanical properties can be improved by the polyester fiber woven base material, and the thermal conductivity can be made closer to the mold resin and the thermal expansion can be made isotropic by the synergistic effect of the two base materials. In addition, the filling state of the loaded resin is improved, and the dielectric breakdown voltage is improved.

According to a ninth aspect of the present invention, the fibrous woven fabric of the first sheet material is an aromatic polyamide fiber woven fabric, and the fibrous nonwoven fabric of the second sheet material is an aromatic polyamide fiber nonwoven fabric. 4. The molded coil according to claim 1, 2, or 3, wherein the structure is such that the aromatic polyamide fiber woven fabric base improves the mechanical properties and the coefficient of thermal expansion with the molding resin. And the change in thermal stress due to temperature change is reduced. Furthermore, by using an aromatic polyamide fiber nonwoven fabric as a base material, the anisotropy of thermal expansion is reduced, and the effective filling rate of the loaded resin is improved by the synergistic effect of both base materials, so that the thermal conductivity and the electrical insulation properties are improved. Become.

According to a tenth aspect of the present invention, the fibrous woven fabric of the first sheet material is an aromatic polyamide fiber woven fabric, and the fibrous nonwoven fabric of the second sheet material is a glass fiber nonwoven fabric. The molded coil according to claim 1, 2, or 3, wherein the aromatic polyamide fiber woven fabric and the glass fiber nonwoven fabric of the base material support and melt and integrate the resin. The thermal expansion coefficient of the composite material is close to that of resin, and the combination of a woven fabric and a non-woven fabric makes thermal expansion isotropic and reduces thermal stress due to temperature change. In addition, the mechanical strength and the electrical properties are improved by a combination of the above two.

According to an eleventh aspect of the present invention, the prepreg resin carried on the fibrous woven fabric of the first sheet material and the fibrous nonwoven fabric of the second sheet material is an epoxy resin. The molded coil according to claim 1, 2, or 3, which has high performance in adhesiveness between sheet materials and with other materials. In addition, the adhesiveness and heat resistance between the fibers of the base material have high electrodynamic performance due to the three-dimensional structure of the carrier resin by heat treatment.

According to a twelfth aspect of the present invention, the prepreg resin carried on the fibrous woven fabric of the first sheet material and the fibrous nonwoven fabric of the second sheet material is an epoxy resin, and the epoxy resin is Gel time at 150 ° C. is 10
The molded coil according to claim 1, 2 or 3, wherein the sheet material supporting the epoxy resin is laminated in addition to the function and effect of claim 11. In this case, the fluidity of the resin can be obtained when integrated, and a solid integrated structure can be formed.

According to a thirteenth aspect of the present invention, the prepreg resin carried on the fibrous nonwoven fabric of the second sheet material is 35% by volume or more. 4,5,6,7,8,9,10,11 or 1
2. The molded coil according to item 2, wherein the resin is sufficiently impregnated in both the base material of the fibrous woven fabric and the non-woven fabric constituting the laminated structure, and is electrically, thermally and mechanically. Excellent performance can be obtained.

The invention according to claim 14 of the present invention is characterized in that at least a part of the inner peripheral material or the outer peripheral material is pressurized at a pressure of 0.01 MPa or more during the curing and melting. , 4,5,6,7,8,9,10,11,
12. The molded coil according to 12 or 13, wherein the pressurization in this manner makes it possible to reduce the air space as much as possible, and to exhibit excellent heat conduction properties, electrical insulation properties, and mechanical properties.

According to a fifteenth aspect of the present invention, the glass transition temperature of the mold resin filled at both ends of the element coil is 100 ° C. or more.
3,4,5,6,7,8,9,10,11,12,13
Or the molded coil according to item 14, wherein the glass transition temperature of the mold resin is 100 ° C. or more, so that the displacement of the coil is small even when the coil is operated at a high temperature, and the thermal, electrical, and mechanical properties are high. Characteristic is maintained.

According to a sixteenth aspect of the present invention, the coil conductor is made of a sheet or flat conductor, and the interlayer insulating material is made of a sheet insulating material. , 4,5,6,7,8,9,10,11,1
2. The molded coil according to 2, 13, 14 or 15, wherein the use of the sheet-like or flat-shaped conductor reduces the electromagnetic force per unit area generated in the conductor, thereby reducing the inner peripheral material and the outer peripheral material. The strength can be reduced. Further, the voltage generated between the conductors on the coil end surface is also reduced. Furthermore, coil end insulation can be simplified.

Hereinafter, an embodiment of the present invention will be described with reference to FIG.
This will be described with reference to FIG.

FIG. 1 is a partial schematic sectional view of a molded coil according to an embodiment of the present invention. In FIG. 1, 1 is a sheet material made of a fibrous woven fabric carrying a prepreg resin, 2 is a sheet material made of a fibrous nonwoven fabric carrying a prepreg resin, 3 is a sheet-shaped coil conductor of aluminum or copper, and 4 is A sheet-like interlayer insulating material made of a polymer film such as PET, PEN, PPS, or polyimide, or a resin-impregnated fibrous material, 5 is a sheet material made of a fibrous fabric supporting a prepreg resin, and 6 is a prepreg resin. A sheet material made of a fibrous nonwoven fabric, 7 is an epoxy resin,
It is a molding resin such as urethane resin or silicon resin, and is formed for the purpose of insulating the coil end. Here, the inner peripheral material composed of the sheet materials 1 and 2 and the outer peripheral material composed of the sheet materials 5 and 6 have substantially the same width, and the sheet-like interlayer insulating material 4 is narrower than those widths. Furthermore, coil conductor 3
(Here, the width of the coil conductor 3) is smaller than the width of the interlayer insulating material 4, and both ends of the element coil between the inner peripheral material and the outer peripheral material are filled with the mold resin 7. Epoxy resin, phenol resin, or the like is used as a prepreg resin for the sheet materials 1, 2, 5, 6, and 6, glass, PET (polyethylene terephthalate) is used as a fibrous material.
Polyester, aromatic polyamide and the like are used.

In this embodiment, the inner peripheral material is wound by laminating a sheet material 1 made of a fibrous woven fabric carrying a prepreg resin and a sheet material 2 made of a fibrous nonwoven fabric carrying a prepreg resin. The laminated structure has been turned. By adopting such a laminated structure, the resin impregnating property is improved, the thermal properties, mechanical properties, and electrical insulation properties are improved, and the isotropy of the thermodynamic behavior is improved. improves. Similarly, the outer peripheral material has a laminated structure in which a sheet material 5 made of a fibrous woven fabric carrying a prepreg resin and a sheet material 6 made of a fibrous nonwoven fabric carrying a prepreg resin are superposed and wound. Has the same effect.

With the above structure, since a strong resin layer does not exist around the inner peripheral material and the outer peripheral material, the decomposability of the element coil is improved, and the reusable coil conductor 3 is recovered. And recyclability is improved.

In FIG. 1, a sheet-shaped conductor 3 is used as the coil winding. However, a similar effect can be obtained by using a flat conductor instead. FIG. 2 shows a partial schematic cross-sectional view of a molded coil when a flat conductor is used.
In FIG. 2, reference numeral 21 denotes a flat coil conductor serving as a coil winding, and the other portions identical to those in FIG. Further, as a configuration of the flat coil conductor 21, there is a configuration shown in the cross-sectional views of FIGS. In FIG. 3, 31 is a conductor such as aluminum or copper, and 32, 33 and 34 are insulating layers.

In FIG. 3A, the conductor 31 is covered with two insulating layers 32 and 33, and the inner insulating layer 32 is
It is made of polyester, polyesterimide, polyimide, epoxy, urethane or the like, and the outer insulating layer 33 is made of one or more materials selected from polyester, polyesterimide, polyimide, epoxy, urethane and the like.

In FIG. 3B, the conductor 31 is connected to the insulating layer 3.
4, the insulating layer 34 is also made of polyester,
It also includes those made of polyesterimide, polyimide, epoxy, urethane, etc., and formed by winding a sheet-like insulating material.

In FIG. 1, a similar effect can be obtained by using a round wire in place of the sheet-shaped conductor 3, but in this case, consideration must be given to the insulation design of the coil end surface.

In the above embodiment, FIGS.
As shown in FIG. 1, both the inner peripheral material and the outer peripheral material have the sheet materials 1 and 5 made of woven fabric on the outer surface side (the inner peripheral surface A of the inner peripheral material and the outer peripheral surface D of the outer peripheral material; see FIG. 1). Sheet materials 2 and 6 are formed on the inner surface (the outer peripheral surface B of the inner peripheral material, the inner peripheral surface C of the outer peripheral material;
Although it is wound so as to be on the side of FIG. 1), when the voltage is low, either side may be on the outer surface side or the inner surface side of the coil. In addition, as shown in FIG. 1 and FIG.
By winding 2,5,6, sheet materials 1,5 made of a woven fabric carrying resin against damage during handling
Is less intense because of the higher strength, and the sheet materials 2 and 6 made of a non-woven fabric carrying the resin are more excellent in the interface characteristics with the mold resin 7, so that the insulation performance (withstand voltage characteristics) is improved. improves.

In the cross-sectional views of FIGS. 1 and 2, the inner peripheral member has a four-layer structure, which may be formed by winding two sheets 1 and 2 twice, or 1,2,1,
It is also possible to stack two and four sheets and wind once.

Next, another embodiment will be described.
In FIG. 1 and FIG. 2, the inner peripheral material and the outer peripheral material are each composed of a different type of sheet material. Only the sheet material 1 made of a woven fabric is used as the inner peripheral material, and the outer peripheral material is used as the outer peripheral material. Is a sheet material 6 made of a nonwoven fabric of a material different from the inner peripheral material.
And a case where only the sheet material 2 made of a nonwoven fabric is used as the inner peripheral material and only the sheet material 5 made of a fabric different from the inner peripheral material is used as the outer peripheral material. There is.

In the transformer, the low-voltage coil and the high-voltage coil are magnetically coupled by an iron core, but the vector of the electromagnetic force acting on each coil differs depending on the arrangement of the low-voltage coil and the high-voltage coil. For example, if the low-voltage coil and the high-voltage coil are arranged concentrically as shown in FIG. 6, mutually repelling electromagnetic forces act. As described above, since the direction in which the stress acts differs depending on the electromagnetic design of the coil, the use of the non-woven sheet materials 2 and 6 for the inner or outer peripheral material that does not apply much stress provides excellent insulation and thermal conductivity. The outer material or the inner material to which a large stress is applied is constituted by the sheet materials 1 and 5 made of a woven fabric having excellent mechanical properties.

According to the other embodiment, FIGS.
Compared with the case of the above, the effect of using two types of sheet materials for the inner peripheral material and the outer peripheral material is not obtained, but since the inner peripheral material and the outer peripheral material are each composed of one type of sheet material, Workability at the time of manufacturing the molded coil is improved. Also in this case, the decomposability of the elementary coil is improved,
It goes without saying that the recyclability is improved.

[0040]

Next, embodiments of the present invention will be described. First, Table 1 shows a part of the outline of the test results of the molded coils of Examples 1 to 10 described later.

[0041]

[Table 1]

In Table 1, the numbers at the left end correspond to Examples 1-1.
Indicates the number of 0. As for coil performance, short-circuit characteristics, temperature rise characteristics, insulation performance, and heat resistance were examined, and the characteristics (coil surface strength, coil surface gloss) are also described. The short-circuit characteristic is based on the result of a short-circuit test in which a current 25 times the rated current is applied for 0.5 seconds. The temperature rise characteristics are the results of examining the temperature rise of the coil conductor by passing a rated current.
It was 95K. The insulation performance is JIS-C-43.
06, a case where a full impulse wave of 60 kV is applied (case), a case where an impulse cutting wave of 65 kV is applied (case), and a case where a withstand voltage of 22 kV and 1 minute are applied (case). As a result of examining, ◎ means that all were satisfied with, 〇 means that 75% was satisfied and was satisfied with, △ means that 60% was satisfied with and was satisfied with, X is a thing which does not stand 50% of. Further, the heat resistance is a result of examining the material system, DTA, and 5% weight loss temperature, and F indicates that the heat resistance category is a level equivalent to Class F (5% weight loss temperature of 385 ° C. or higher). Table 1 also shows Comparative Examples I and II.

In Example 1, a sheet material (CFR) composed of a fibrous woven fabric carrying a prepreg resin and a sheet material (NFR) composed of a fibrous nonwoven fabric carrying a prepreg resin were used for both the inner and outer peripheral materials. Are superposed and wound to form a composite laminated structure. Here, as for the inner peripheral material, as shown in FIG. 1, a sheet material 1 made of a fibrous woven fabric carrying a prepreg resin is disposed on an inner peripheral surface A of the inner peripheral material, and the prepreg resin is carried on an outer peripheral surface B. The sheet material 2 made of a fibrous non-woven fabric is wound so as to be arranged. However, as for the outer peripheral material, contrary to FIG. 1, the fibrous material in which the prepreg resin is supported on the inner peripheral surface C of the outer peripheral material is used. A sheet material (5) made of a woven fabric is arranged, and the sheet material (6) made of a fibrous nonwoven fabric carrying a prepreg resin is wound around the outer peripheral surface D.

In Example 2, a sheet material (CFR) made of a fibrous woven fabric carrying a prepreg resin and a fiber material carrying a prepreg resin were used in which different sheet materials were used for an inner peripheral material and an outer peripheral material. (N)
FR) and one of them is used as an inner peripheral member, and the other is used as an outer peripheral member. In Table 1, CFR is used for the inner peripheral material and NFR is used for the outer peripheral material.
Example 2 includes both the case where CFR is used as the outer peripheral material and the case where CFR is used as the outer peripheral material.

In Example 3, a sheet material (CFR) composed of a fibrous woven fabric carrying a prepreg resin and a sheet material (NFR) composed of a fibrous nonwoven fabric carrying a prepreg resin were used for both the inner and outer peripheral materials. 1 in which the sheet materials 1 and 5 made of woven fabric are on the outer surface side, and the sheet materials 2 and 6 made of non-woven fabric are on the inner surface where they are in contact with the mold resin 7. It is wound so that it becomes.

In the first to third embodiments, the prepreg resin and the fibrous material of the sheet material used as the inner and outer peripheral materials are the same, respectively. Here, the epoxy resin is used as the prepreg resin, and the fibrous material is used as the fibrous material. Glass fiber is used.

As shown in Table 1, Examples 1 to 3
All of them have good short-circuit characteristics, and the heat resistance is at the level of class F in the heat resistance category. In the second embodiment, the temperature rise characteristics and the insulation performance are inferior to those of the first and third embodiments. However, since both the inner peripheral member and the outer peripheral member are composed of one type of sheet material, workability is improved. Further, in Example 3, as shown in FIG.
Is brought into contact with the mold resin 7, so that the withstand voltage at the interface with the mold resin 7 is improved.

In Comparative Example I, both the inner and outer peripheral members were constituted only by a sheet material (CFR) made of a fibrous woven fabric carrying a prepreg resin. In this case, the strength of the coil surface was low. High (〇), the gloss on the coil surface becomes poor (x). Further, in Comparative Example II, both the inner and outer peripheral materials were constituted only by a sheet material (NFR) made of a fibrous nonwoven fabric carrying a prepreg resin, and in this case, the strength of the coil surface was low ( ×)
However, the gloss of the coil surface becomes good (〇). Example 1,
In the case of the second embodiment, the CFR is disposed on one outer surface of the inner peripheral member and the outer peripheral member, and the NFR is disposed on the other outer surface. The surface becomes higher but the outer surface on which the NFR is arranged becomes lower (△). In the case of the second embodiment, the gloss of the coil surface is worse on the outer surface where the CFR is arranged, but is better on the outer surface where the NFR is arranged (△). In the case of Example 1,
The gloss of the coil surface is worse than Comparative Example II using only NFR, but better than Comparative Example I using only CFR (△). In Example 3, since the CFR is disposed on the outer surface of both the inner and outer peripheral materials, the strength of the coil surface is increased (〇), and the gloss of the coil surface is worse than that of Comparative Example II using only NFR. Comparative Example I using only CFR
It will be better (△).

Embodiments 4 to 10 are the same as Embodiment 3 in FIG.
In each of the examples, the base material (fibrous material supporting the prepreg resin) constituting the sheet material is different. As in the first to third embodiments, an epoxy resin is used as the prepreg resin of the sheet material used for the inner and outer peripheral members.

In the fourth embodiment, a sheet having a glass fiber woven fabric as a base material and a sheet material using a glass fiber nonwoven fabric as a base material are overlapped and wound for both the inner and outer peripheral materials. This is the same as Example 3 when glass fiber is used. The use of the glass fiber woven fabric and the non-woven fabric is characterized in that the inner peripheral material and the outer peripheral material have high heat deformation temperatures.

In the fifth embodiment, for both the inner and outer peripheral materials, a sheet material using a glass fiber fabric as a base material and a sheet material using a polyester fiber nonwoven fabric as a base material are superposed and wound to form a composite laminated structure. I have to. As described above, by using the polyester fiber nonwoven fabric, the thermal expansion coefficient becomes closer to that of the mold resin as compared with the fourth embodiment.

In the sixth embodiment, a sheet material using a glass fiber fabric as a base material and a sheet material using an aromatic polyamide fiber non-woven fabric as a base material are superposed and wound on both inner and outer circumferential materials. It has a laminated structure. As described above, by using the aromatic polyamide fiber nonwoven fabric, the heat resistance is higher than that of Example 5.

In the seventh embodiment, a sheet material using a polyester fiber woven fabric as a base material and a sheet material using a polyester fiber nonwoven fabric as a base material are overlapped and wound for both the inner and outer circumferential materials. I have to. By using a woven fabric and a non-woven fabric of polyester fibers, the coefficient of thermal expansion becomes close to that of the mold resin.

In the eighth embodiment, a sheet material using a polyester fiber woven fabric as a base material and a sheet material using a glass fiber non-woven fabric as a base material are superposed and wound on both the inner and outer circumferential materials. I have to. Thereby, the isotropy of thermal expansion becomes high.

In Example 9, a sheet material using an aromatic polyamide fiber woven fabric as a base material and a sheet material using an aromatic polyamide fiber non-woven fabric as a base material were superposed and wound on both the inner and outer peripheral materials. It has a rotating composite laminated structure. Thereby, the thermal expansion is close to that of the resin, and the heat resistance is increased.

In the tenth embodiment, a sheet material using an aromatic polyamide fiber fabric as a base material and a sheet material using a glass fiber nonwoven fabric as a base material are superposed and wound on both the inner and outer peripheral materials. It has a laminated structure. Thereby, thermal expansion is isotropic and heat resistance is increased.

Here, for example, a method of manufacturing the molded coil shown in FIG. 1 will be described. First, a bobbin, that is, an inner peripheral member is manufactured. In this method, after the sheet materials 1 and 2 are wound, pressure (0.01 MPa or more) and heating (150 ° C.) are simultaneously performed. Thereby, the resin (epoxy resin) carried on the sheet materials 1 and 2 is temporarily melted and then cured. here,
The epoxy resin supported on the sheet materials 1 and 2 is 150 ° C.
When the gel time in is 10 minutes or more, the fluidity of the resin is obtained when the sheet materials are laminated and integrated,
A strong laminated structure can be achieved.

Next, the conductor 3 and the interlayer insulating material 4 are wound around the bobbin. Thereafter, sheet materials 5 and 6 are wound as an outer peripheral material, and pressurized (0.01 MPa or more) and heated (150 MPa).
° C) at the same time. Also here, the epoxy resin carried on the sheet materials 5 and 6 has a gelling time at 150 ° C. of 10 minutes or more, so that the fluidity of the resin is obtained when the sheet materials are laminated and integrated. , A strong laminated structure.

Next, the molding resin 7 is injected into the coil end, and heated to 100 to 150 ° C. to impregnate the molding resin into the details of the coil end, and then cured.

In the above Examples 1 to 10, the use of an epoxy resin as the prepreg resin of the sheet material allows the adhesiveness between the sheet materials and other materials, the adhesiveness between the fibers of the base material and the heat resistance. High strength, small deformation at high temperature, and high strength. Furthermore, since the epoxy resin has a gelation time at 150 ° C. of 10 minutes or more, the fluidity of the resin is obtained when laminating and integrating the sheet materials supporting the epoxy resin, and a strong integrated structure is obtained. A laminated structure can be formed. When the gelling time of the epoxy resin at 150 ° C. is less than 10 minutes, the flow of the resin is poor, the integrity of the sheet materials (layers) is lost, and the thermal conductivity and the electrical insulation properties are poor. Conversion time 1
In the case of 0 minutes or more, excellent performance is obtained.

In each of the embodiments except the embodiment 2,
By setting the amount of the prepreg resin such as epoxy resin carried on the fibrous nonwoven fabric of one sheet material to 35% by volume or more, the resin is applied to both the fibrous woven fabric and the nonwoven fabric constituting the laminated structure. It is sufficiently impregnated, has high strength, and is excellent in thermal conductivity and withstand voltage.

In Examples 1 to 10, at least a part of the inner peripheral material or the outer peripheral material is pressurized at a pressure of 0.01 MPa or more during curing and melting, so that the air space can be reduced as much as possible. More excellent heat conduction characteristics, electrical insulation characteristics, and mechanical characteristics can be exhibited.
If the above-mentioned pressing force is less than 0.01 MPa (including the case where no pressure is applied), a gap is formed between the layers of the sheet material, and the above-mentioned characteristics are inferior.

Further, in the above Examples 1 to 10, the glass transition temperature of the mold resin 7 filling both ends of the element coil is 100 ° C. or more. The displacement is small and the thermal, electrical and mechanical properties are maintained. For example, a decrease in strength at a practical temperature is reduced. For example, when the glass transition temperature of the mold resin 7 at the coil end is about 80 to 90 ° C., the heat-resistant class is at the level of Class B, it is difficult to use it at Class F, and if the glass transition temperature is 100 ° C. or higher. If this is the case, it will be of the F type.

Further, in the case of the conventional high voltage coil 60 shown in FIG. 6, for example, the periphery is covered with a strong mold resin 57, so that it cannot be dismantled and the recycling rate is 0%.
On the other hand, in the case of Examples 1 to 10 described above, the insulating material and the conductor could be separated, and the recycling rate was about 75 to 80% because the usage ratio of the insulating material was reduced.

In the first to tenth embodiments, the sheet conductor is used as the coil conductor as shown in FIG. 1. However, the same effect can be obtained by using a flat conductor or a round wire. However, by using a sheet-shaped or flat conductor, the electromagnetic force per unit area generated in the conductor is reduced, and the strength of the inner peripheral member and the outer peripheral member can be reduced. Also,
The voltage generated between the conductors at the coil end face also decreases. Furthermore, coil end insulation can be simplified. Therefore, insulation reliability and short-circuit characteristics are improved.

The detailed operation and effect of each of the above embodiments are the same as those described in each claim at the beginning of the embodiment of the present invention.

[0067]

As described above, according to the present invention, excellent effects are obtained with respect to insulation performance such as temperature rise characteristics and impulse characteristics, mechanical characteristics such as short-circuit tests, heat resistance, and recyclability. Further, since the material configuration is simple, the use efficiency of the material is high, and further, the production is simple and energy saving in the production process can be realized.

That is, according to the first aspect of the present invention, the inner peripheral material and the outer peripheral material are formed of a first sheet material in which a prepreg resin is supported on a fibrous woven fabric, and a prepreg resin is formed on a fibrous nonwoven fabric. Is laminated with a second sheet material carrying the same, and wound to form a composite laminated structure. Since the base material of the inner peripheral material and the outer peripheral material is a composite structure of a woven fabric and a non-woven fabric, the electrical insulation properties and mechanical properties The effective resin filling rate is high, the thermal conductivity is improved, and at the same time, the decomposability of the element coil is improved because there is no strong resin layer around the inner and outer peripheral materials. And the recyclability is improved.

According to the second aspect of the present invention, the first sheet material in which the prepreg resin is supported on the fibrous woven fabric and the second sheet material in which the prepreg resin is supported on the fibrous nonwoven fabric are used. One of the sheet materials is wound to form an inner circumferential material, and the other sheet material is wound to form an outer circumferential material. With such a configuration, the inner circumferential material and the outer circumferential material are surrounded. Since there is no strong resin layer, the decomposability of the element coil is improved, and the recyclability is improved. In addition, since the inner peripheral member and the outer peripheral member are each composed of one type of sheet material, workability in manufacturing the molded coil is improved. In addition, in this configuration, since the direction in which the stress acts depends on the electromagnetic design of the coil, the insulating and thermal conductivity are excellent by using a sheet material made of a nonwoven fabric for the inner peripheral material or the outer peripheral material that does not apply much stress. The outer peripheral material or the inner peripheral material to which a large stress is applied is constituted by a sheet material made of a woven fabric having excellent mechanical properties.

According to the third aspect of the present invention, the inner peripheral material and the outer peripheral material are each provided with the first sheet material in which the prepreg resin is supported on the fibrous fabric on the outer surface. It is characterized by the fact that the inner peripheral surface of the inner peripheral material and the outer peripheral surface of the outer peripheral material, which is the outer surface, are made of a sheet material having a woven fabric as a base material. Damage is reduced, and the dielectric strength at the interface with the mold resin is also improved.

According to the fourth aspect of the present invention, the fibrous fabric of the first sheet material is a glass fiber fabric,
The fibrous nonwoven fabric of the second sheet material is a glass fiber nonwoven fabric, and the base material of the inner peripheral material and the outer peripheral material is glass fiber, so that the heat conductivity is excellent, and the thermal expansion coefficient is glass fiber. Because of the laminated structure of non-woven fabric and woven fabric, the base material is closer to the mold resin than the glass fiber woven fabric alone.
Small change in internal stress due to temperature change.

According to the fifth aspect of the present invention, the fibrous woven fabric of the first sheet material is a glass fiber woven fabric,
The fibrous nonwoven fabric of the second sheet material is a polyester fiber nonwoven fabric, and the base material of the inner peripheral material and the outer peripheral material is a glass fiber woven fabric and a polyester fiber nonwoven fabric. The difference is small, and the occurrence of thermal stress with respect to temperature change is small. Further, since the filling of the resin is improved, the electric insulation property, particularly the dielectric breakdown voltage is high, and the thermal conductivity is also improved.

According to the invention of claim 6 of the present invention, the fibrous fabric of the first sheet material is a glass fiber fabric,
The fibrous nonwoven fabric of the second sheet material is an aromatic polyamide fiber nonwoven fabric, and the base material of the inner peripheral material and the outer peripheral material is made of a glass fiber woven fabric and an aromatic polyamide fiber nonwoven fabric. It is very excellent, has a coefficient of thermal expansion close to that of resin, and has excellent mechanical properties due to the synergistic effect of the glass fiber fabric and the aromatic polyamide fiber nonwoven fabric.

According to the seventh aspect of the present invention, the fibrous woven fabric of the first sheet material is a polyester fiber woven fabric, and the fibrous nonwoven fabric of the second sheet material is a polyester fiber nonwoven fabric. Because the base material of the inner and outer materials is polyester fiber, the difference in the coefficient of thermal expansion between the resin and the resin is small. The thermal conductivity is also improved because the base material is better filled with resin than the woven fabric alone.

According to the eighth aspect of the present invention, the fibrous woven fabric of the first sheet material is a polyester fiber woven fabric, and the fibrous nonwoven fabric of the second sheet material is a glass fiber nonwoven fabric. The mechanical properties are improved by the polyester fiber woven base material, and the thermal conductivity is brought closer to the mold resin by the synergistic effect of the two base materials, and the thermal expansion is made isotropic. In addition, the filling state of the loaded resin is improved, and the dielectric breakdown voltage is improved.

According to the ninth aspect of the present invention, the fibrous woven fabric of the first sheet material is an aromatic polyamide fiber woven fabric, and the fibrous nonwoven fabric of the second sheet material is an aromatic polyamide fiber. It is characterized by being a non-woven fabric, and by using an aromatic polyamide fiber woven fabric base material, it is possible to improve the mechanical properties and reduce the difference in thermal expansion coefficient from the mold resin, and reduce the change in thermal stress due to temperature change. Furthermore, by using an aromatic polyamide fiber nonwoven fabric as a base material, the anisotropy of thermal expansion is reduced, and the effective filling rate of the loaded resin is improved by the synergistic effect of both base materials, so that the thermal conductivity and the electrical insulation properties are improved. Become.

According to the tenth aspect of the present invention,
The fibrous woven fabric of the first sheet material is an aromatic polyamide fiber woven fabric, and the fibrous nonwoven fabric of the second sheet material is a glass fiber nonwoven fabric. The fiber non-woven fabric carries the resin and melts and integrates it, so that the thermal expansion coefficient as a composite material is close to that of the resin, and the combination of the woven fabric and the non-woven fabric makes the thermal expansion isotropic and reduces the thermal stress due to temperature change. . Further, the mechanical strength and the electrical characteristics are also improved by a combination of the two.

According to the eleventh aspect of the present invention,
The prepreg resin carried on the fibrous nonwoven fabric of the first sheet material and the fibrous nonwoven fabric of the second sheet material is an epoxy resin, and the adhesiveness between the sheet materials and with other materials is also characterized. Has high performance. In addition, the adhesiveness and heat resistance between the fibers of the base material have high electrodynamic performance due to the three-dimensional structure of the carrier resin by heat treatment.

According to the invention of claim 12 of the present invention,
The prepreg resin supported on the fibrous nonwoven fabric of the first sheet material and the fibrous nonwoven fabric of the second sheet material is an epoxy resin, and the epoxy resin has a gel time at 150 ° C. of 10 minutes or more. In addition to the functions and effects of the eleventh aspect, when the sheet materials carrying the epoxy resin are laminated and integrated, fluidity of the resin is obtained, and a strong integrated structure can be formed. .

According to the thirteenth aspect of the present invention,
The prepreg resin carried on the fibrous nonwoven fabric of the second sheet material is 35% by volume or more,
The resin is sufficiently impregnated in both the fibrous woven fabric and the nonwoven fabric constituting the laminated structure, and excellent electrical, thermal and mechanical performance can be obtained.

According to the fourteenth aspect of the present invention,
It is characterized in that at least a part of the inner peripheral material or the outer peripheral material is pressurized at a pressure of 0.01 MPa or more during curing and melting, and by being pressurized in this manner, it is possible to reduce the air space as much as possible, Excellent heat conduction, electrical insulation and mechanical properties can be exhibited.

According to the fifteenth aspect of the present invention,
The glass transition temperature of the mold resin filling both ends of the elementary coil is 100 ° C. or higher. With this configuration, even when the coil is operated at a high temperature, the displacement of the coil is small, The electrical, electrical and mechanical properties are maintained.

According to the sixteenth aspect of the present invention,
The coil conductor is formed of a sheet-shaped or flat-shaped conductor, and the interlayer insulating material is formed of a sheet-shaped insulating material,
By using a sheet-like or flat conductor as described above, the electromagnetic force per unit area generated in the conductor is reduced, and the strength of the inner peripheral member and the outer peripheral member can be reduced. Further, the voltage generated between the conductors on the coil end surface is also reduced. Furthermore, coil end insulation can be simplified.

[Brief description of the drawings]

FIG. 1 is a partial schematic cross-sectional view of a molded coil according to an embodiment of the present invention.

FIG. 2 is a partial schematic cross-sectional view of a molded coil according to an embodiment of the present invention.

FIG. 3 is a schematic sectional view of a flat coil conductor.

FIG. 4 is a partial schematic cross-sectional view of an elementary coil used for a conventional molded coil.

FIG. 5 is a partial schematic cross-sectional view of a conventional molded coil.

FIG. 6 is a partially cutaway schematic view of a conventional mold transformer.

[Explanation of symbols]

Reference Signs List 1 sheet material made of fibrous woven fabric carrying prepreg resin 2 sheet material made of fibrous nonwoven fabric carrying prepreg resin 3 sheet-shaped coil conductor 4 interlayer insulating material 5 made of fibrous woven fabric carrying prepreg resin Sheet material 6 Sheet material made of fibrous nonwoven fabric carrying prepreg resin 7 Mold resin 21 Flat coil conductor

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI theme coat ゛ (Reference) H01F 27/28 H01F 27/28 K (72) Inventor Yoshimasa Haraguchi 1006 Kazuma Kazuma, Kadoma, Osaka Matsushita Electric F-term (reference) in Sangyo Co., Ltd. 5E043 AA01 BA01 BA04 5E044 AC01 AD03 CA02 CB03 CB06 CB09 5E048 CB01

Claims (16)

[Claims] An outer peripheral member having a width substantially equal to the inner peripheral member is provided on an outer periphery of an element coil in which a coil conductor and an interlayer insulating material are wound around the inner peripheral member with a width smaller than the width of the inner peripheral member; A mold coil in which a mold resin is filled at both ends of the element coil between an inner peripheral material and an outer peripheral material, wherein the inner peripheral material and the outer peripheral material are a first material in which a prepreg resin is supported on a fibrous fabric. A mold coil, wherein a sheet material and a second sheet material in which a prepreg resin is supported on a fibrous nonwoven fabric are overlapped and wound to form a composite laminated structure. 2. An outer peripheral material having a width substantially equal to the inner peripheral material is provided on the outer periphery of a coil in which a coil conductor and an interlayer insulating material are wound around the inner peripheral material with a width smaller than the width of the inner peripheral material. A molded coil in which both ends of the element coil between an inner peripheral material and an outer peripheral material are filled with a mold resin, wherein a first sheet material in which a prepreg resin is supported on a fibrous fabric, and a fibrous nonwoven fabric are formed. Second supporting prepreg resin
Wherein the one or more sheet materials are wound to form the inner peripheral material, and the other sheet material is wound to form the outer peripheral material. 3. The inner peripheral member and the outer peripheral member are provided with a first sheet member having a prepreg resin supported on a fibrous woven fabric on an outer surface of each of the inner peripheral member and the outer peripheral member. The described molded coil. 4. The fibrous nonwoven fabric of the first sheet material is a glass fiber nonwoven fabric, and the fibrous nonwoven fabric of the second sheet material is a glass fiber nonwoven fabric. The described molded coil. 5. The fibrous woven fabric of the first sheet material is a glass fiber woven fabric, and the fibrous nonwoven fabric of the second sheet material is a polyester fiber nonwoven fabric. The described molded coil. 6. The fibrous woven fabric of the first sheet material is a glass fiber woven fabric, and the fibrous nonwoven fabric of the second sheet material is an aromatic polyamide fiber nonwoven fabric. Or the molded coil of 3. 7. The fibrous woven fabric of the first sheet material is a polyester fiber woven fabric, and the fibrous nonwoven fabric of the second sheet material is a polyester fiber nonwoven fabric. The described molded coil. 8. The fibrous woven fabric of the first sheet material is a polyester fiber woven fabric, and the fibrous nonwoven fabric of the second sheet material is a glass fiber nonwoven fabric. The described molded coil. 9. The fibrous nonwoven fabric of the first sheet material is an aromatic polyamide fiber nonwoven fabric, and the fibrous nonwoven fabric of the second sheet material is an aromatic polyamide fiber nonwoven fabric. , 2 or 3. 10. The fibrous woven fabric of the first sheet material is an aromatic polyamide fiber woven fabric, and the fibrous nonwoven fabric of the second sheet material is a glass fiber nonwoven fabric. Or the molded coil of 3. 11. The prepreg resin carried on the fibrous woven fabric of the first sheet material and the fibrous nonwoven fabric of the second sheet material is an epoxy resin.
4. The molded coil according to 2 or 3. 12. The prepreg resin carried on the fibrous woven fabric of the first sheet material and the fibrous nonwoven fabric of the second sheet material is an epoxy resin, and the epoxy resin is one of the following.
4. The molded coil according to claim 1, wherein the gelation time at 50 [deg.] C. is 10 minutes or more. 13. The prepreg resin carried on the fibrous non-woven fabric of the second sheet material is at least 35% by volume. ,
13. The molded coil according to 9, 10, 11 or 12. 14. The method according to claim 1, wherein at least a part of the inner peripheral material or the outer peripheral material is pressurized at a pressure of 0.01 MPa or more during curing and melting.
The molded coil according to 7, 8, 9, 10, 11, 12, or 13. 15. The method according to claim 1, wherein the glass transition temperature of the mold resin filled at both ends of the element coil is 100 ° C. or higher. 1
15. The molded coil according to 0, 11, 12, 13 or 14. 16. The method according to claim 1, wherein the coil conductor is made of a sheet-shaped or flat conductor, and the interlayer insulating material is made of a sheet-shaped insulating material.
The molded coil according to 8, 9, 10, 11, 12, 13, 14 or 15.