JP2002050516A - Method of molding air-core coil - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of molding an air-core coil, with which lead-out wires will not be exposed on the surface of the mold resin and which will not generate dielectric breakdown failures, even after assembly of the molded air-core coil. SOLUTION: A trapezoidal air-core coil 1a has a winding part 1B, wound by a self-fusible insulated wire and an opening 1C. An initial-winding side lead wire 2A and a final-winding side lead wire 2B of the air-core coil are led out from the central vicinity of a short side A of the air-core coil along the side face or the upper face of the winding part 1B. Molding is performed, by using molds 5A, 5B which have a split mold 5C. The split mold 5C presses prescribed parts of the initial-winding-side lead wire 2A and the final-winding-side lead wire 2B of the air-core coil 1a to the winding part 1B, which are led out from the central vicinity of the short side A of the air-core coil, so as not to expose the lead wires 2A, 2B on the surface of the mold resin 4.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention
The present invention relates to a method of molding an air-core coil used for a (voice coil motor) or the like. In particular, when holding and fixing an air-core coil having a winding portion and an opening integrally with a mold resin, the lead of the air-core coil is used. The present invention relates to a method for molding an air-core coil that does not expose a wire drawing portion to a mold resin surface.

[0002]

2. Description of the Related Art FIG. 3 shows a conventional mold molding in which a winding resin 1B formed by winding a self-fusing insulated wire and an air-core coil 1a having an opening 1C are integrally held and fixed by a molding resin 4. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1A is a perspective view showing a configuration of a molded air-core coil 1A, and FIG.
(b) is an enlarged sectional view taken along the line XX in a circle in FIG.
FIG. 3 is a perspective view showing a configuration of a trapezoidal air core coil 1a. By the way, in the molding by the conventional method, in order to prevent the winding start side lead wire 2A and the winding end side lead wire 2B of the air core coil 1a from being exposed on the surface of the mold resin 4 after the molding, the lead wires 2A, 2B It has been necessary to mold and mold a predetermined portion of the drawn-out portion to the outer peripheral surface of the coil winding portion 1B with an adhesive 7 or the like.

[0003]

The reason for this is that if the lead wires 2A and 2B are drawn out without bonding and fixed and molded, the lead wires 2A and 2B drawn out are exposed on the surface of the molding resin 4 during molding. This is because, for example, after assembly of the molded air-core coil, there is an extremely large risk of causing a defect such as a withstand voltage failure between the support plate and the like for supporting and fixing the air-core coil. Line 2A, 2
It was necessary to securely fix the lead-out portion to the surface of the winding portion 1B with the adhesive 7. However, in order to fix the lead wire 2A, 2B lead-out portion to the surface of the winding portion 1B, the adhesive 7 is applied in a state where at least a part of the lead wire 2A, 2B lead-out portion is in close contact with the surface of the winding portion 1B. , A curing step was required.
For this reason, the number of manufacturing steps in the molding of the air-core coil is increased, and in addition to the odor peculiar to the adhesive 7, it is necessary to take measures against outgassing.

Accordingly, an object of the present invention is to prevent the lead-out portion from being exposed on the surface of the molded resin even when the air-core coil is molded, and a dielectric breakdown voltage failure occurs even after the molded air-core coil is assembled. It is an object of the present invention to provide a method of molding an air-core coil that does not use the same.

[0005]

SUMMARY OF THE INVENTION In a first aspect, the present invention provides a winding start side lead wire 2A of a trapezoidal air-core coil having a winding portion 1B wound with a self-fusing insulated wire and an opening 1C. And the winding end 1B from the vicinity of the center of the short side A of the air core coil.
A method for molding an air-core coil that is drawn out and molded along the side or upper surface of the air-core coil, wherein the air-core coil 1a is drawn out from near the center of the air core coil short side A side.
Having a split mold 5C for pressing predetermined portions of the winding start side lead wire 2A and the winding end side lead wire 2B on the short side A side of the winding portion 1B.
A method for molding an air-core coil, characterized in that molding is performed using 5A and 5B, and the lead wires 2A and 2B are not exposed on the surface of the molding resin 4. In the method of molding the air-core coil according to the first aspect, the trapezoidal air-core coil 1a is formed of a winding start side lead wire 2A and a winding end side lead wire 2B drawn out from near the center on the short side A side of the air core coil. A predetermined part is pressed against the outer surface of the winding part 1B by a split mold 5C and molded in a state in which the lead part 2A, 2B lead-out part is prevented from being exposed to the surface of the molding resin 4, so that the lead wire 2
The work of fixing the A and 2B drawing parts to the winding part 1B with an adhesive becomes unnecessary. As a result, the number of manufacturing steps in molding the air-core coil is reduced, and an inexpensive molded coil can be provided.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments Hereinafter, the present invention will be specifically described with reference to the embodiments shown in the drawings. FIG. 1 is a simplified explanatory view of an air-core coil obtained by the molding method of the present invention. FIG. 1 (a) is a perspective view showing the structure, and FIG. 1 (b) is a circle mark in FIG. It is a XX line partial expanded sectional view in the inside. FIG. 2 is an explanatory diagram showing an outline of a molding method according to the present invention. Note that the present invention is not limited by this.

In FIG. 1, reference numeral 1a denotes a trapezoidal winding of a self-fusing insulated wire with a predetermined number of turns using a generally used winding machine and a winding form (not shown), and hot air. It is an air-core coil formed into a trapezoidal shape by heat-sealing with a winding portion 1B and an opening 1C. When the air core coil 1a is molded, the winding start side lead wire 2A pulled out from the inner layer side of the winding portion 1B, and the winding end side lead wire 2B on the outer surface side of the winding portion 1B, The terminal portion is pre-processed so as to be drawn out from the vicinity of the approximate center of the short side A of the winding portion 1B along the short side A side surface of the winding portion 1B.

Reference numerals 5A, 5B, and 5C denote dies which are combined with each other and used to mold the air-core coil 1a.
Are the mold insertion grooves 5D, 5D provided in the upper and lower molds 5A, 5B, respectively.
This is a split mold that is inserted into a mold insertion hole (not shown) formed by the above and presses a part of the lead-out portion of the lead wires 2A, 2B against the side surface on the short side A side of the winding portion 1B. 3 is mold 5A, 5B
Lead wire outlets provided for each, and lead wires 2A, 2B pressed against the short side A side surface of winding part 1B by split type 5C
A space is formed for drawing out the drawn part from the upper and lower molds 5A and 5B.

According to the present invention, the trapezoidal air-core coil 1a is positioned by using a positioning projection or the like (not shown) provided in the mold 5A and arranged in the mold 5A.
The mold 5A and the mold 5B are combined so that the lead wires 2A and 2B are drawn out from the lead wire outlet 3. Also mold 5
By combining A and 5B, the split mold 5C is inserted into the mold insertion hole formed by the mold insertion grooves 5D and 5D, and a predetermined portion of the lead wire 2A and 2B is drawn out from the short side A side of the winding portion 1B. It becomes possible to make it hold down on the side.

Here, a mold resin 4 of PPS (polyphenylene solphite) or polyester is injected into the molds 5A and 5B, and the mold resin 4 is cured to form the molds 5A and 5B.
As shown in the drawing, as shown in the drawing, the lead wires 2A and 2B lead-out portions are attached to the winding portion 1B short side A side surface by the split mold 5C,
In addition to being exposed on the surface of the mold resin, the air core coil 1 molded by forming the space 8 is obtained. In addition, the space 8 part is a split mold 5C at the time of molding.
The surface of the mold resin 4 and the lead 2
The distance between A and 2B is set in advance to a value that satisfies the withstand voltage.

According to the present invention, at the time of molding the air-core coil, the lead wire lead-out portion is not exposed on the surface of the mold resin, and the occurrence of insulation withstand voltage failure after the air-core coil is assembled after the molding is eliminated. As a result, the work of fixing the lead-out portions of the lead wires 2A and 2B with the adhesive becomes unnecessary, and an inexpensive air-core coil with a reduced number of manufacturing steps can be obtained.

[0012]

According to the present invention, when molding an air-core coil, it is not necessary to fix the winding start side lead wire and the winding end side lead wire lead-out portion with the adhesive which was required in the past, and the manufacturing process is completed. It becomes possible to provide an inexpensive air-core coil with a reduced number of steps. The practical effect is large.

[Brief description of the drawings]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a simple explanatory view of an air-core coil obtained by the present invention, wherein FIG. 1 (a) is a perspective view showing the configuration, and FIG.
FIG. 3A is an enlarged cross-sectional view taken along a line XX in a circle in FIG.

FIG. 2 is an explanatory view schematically showing a molding method according to the present invention.

FIGS. 3A and 3B are simplified explanatory views showing a conventional example, in which FIG. 3A is a perspective view showing a molded air-core coil 1A, and FIG. 3B is a XX in a circle in FIG. FIG. 4C is a perspective view showing the configuration of the trapezoidal air core coil 1a.

[Explanation of symbols]

 1,1A Air-core coil 1a Air-core coil 1B Winding part 1C Opening 2A Beginning lead wire 2B End winding lead wire 3 Lead wire outlet 4 Mold resin 5A, 5B Mold 5C Split mold 5D mold insertion groove 7 Adhesive 8 Space A Short side

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) H01F 41/02 H01F 15/10 H (72) Inventor Keiji Kudo 300 Oya Oya, Ueda-shi, Nagano Pref. F-term in Ueda Factory Co., Ltd. (reference) 5E043 AA01 EA01 EA05 EA06 5E048 CB01 CB03 5E062 AA06 AB20 FF02 FG12 5E070 EA06

Claims (1)

[Claims] 1. A winding portion 1B on which a self-fusing insulated wire is wound.
Lead wire of a trapezoidal air-core coil having a hole and an opening 1C
2A and a winding end side lead wire 2B are drawn out from the vicinity of the center of the short side A side of the air core coil along the side surface or upper surface of the winding portion 1B and molded. A split mold 5C is provided for pressing predetermined portions of the winding start side lead wire 2A and the winding end side lead wire 2B of the air core coil 1a to be pulled out from the vicinity of the central portion on the core coil short side A side to the winding section 1B short side A side. A molding method of an air-core coil, wherein molding is performed using dies (5A, 5B), and lead wires (2A, 2B) are not exposed on the surface of molding resin (4).