JP2002286050A - Electromagnetic coil device and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To swiftly deliver a molding material to every corner of a coil body. SOLUTION: Communication holes 15a, 15b, 15c communicating with the innermost layer of a coil body 13 and forming passages for a uncured molding material 14 are provided respectively in the winding part 12a of a bobbin 12, a first flange section 12b, and a second flange section 12c.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an electromagnetic coil device used for, for example, an electric motor or an electromagnetic clutch, and a method of manufacturing the same.

[0002]

2. Description of the Related Art In a conventional electromagnetic coil device, in order to fix a coil body to an iron core and to release Joule heat generated in the coil body to the outside, the coil body is molded with a molding material such as varnish or resin. A method of molding is known. In order to firmly fix the coil body,
It is required that the molding material itself is strong and does not peel or fall off the iron core. In addition, in order to quickly release heat, it is effective to fill the inside and outside of the coil body with a gap without any gap.

FIG. 6 is an explanatory view showing a molding method of a conventional electromagnetic coil device disclosed in, for example, JP-A-11-136911, and shows a molding method by a casting method. In the pouring method, after the coil body 2 is inserted into the shell 1, the resin composition 3 is poured into a gap between the shell 1 and the coil body 2. Thereafter, the resin composition 3 is cured by heating.

FIG. 7 is an explanatory view showing another molding method of a conventional electromagnetic coil device, and shows a molding method by an injection molding method. In the injection molding method, the shell 1 into which the coil main body 2 is inserted is set in a molding machine receiving mold 4. The uncured resin composition 3 is inserted into a cylinder 6 formed in the upper mold 5.

Thereafter, when the piston 7 slides in the cylinder 6, the resin composition 3 is injected into the shell 1 from the injection port 8, and the inside of the shell 1 is evacuated from the suction port 9. . Thereafter, the resin composition 3 is heated and cured by the heater 10 arranged in the molding machine receiving mold 4.

[0006]

In the conventional molding methods as described above, it is difficult to spread the resin composition 3 sufficiently between the conductors of the coil body 2 by any of the methods. Imperfect impregnation may occur. In particular, when the coil main body 2 having a large number of turns of several hundred turns or more is used, impregnation failure is likely to occur in an inner layer portion of the coil main body 2 or a portion away from the injection port 8.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-described problems, and provides an electromagnetic coil device capable of spreading a molding material to every corner of a coil body and a method of manufacturing the same. The purpose is to:

[0008]

According to the first aspect of the present invention, there is provided an electromagnetic coil device comprising: a tubular winding portion; and first and second flange portions provided at both ends of the winding portion and opposed to each other. A coil body wound around the winding portion between the first and second flange portions, a bobbin receiving surface facing the second flange portion, and a bobbin projecting from the bobbin receiving surface. A protrusion that is inserted inside, an iron core having an inner wall surface facing the outer peripheral portion of the coil body, and a molding material filled and cured between the bobbin and the iron core and between the conductors of the coil body, The bobbin is provided with a communication path communicating with the innermost layer of the coil body and serving as a flow path for the uncured molding material.

According to a second aspect of the present invention, there is provided an electromagnetic coil device comprising:
A communication hole, which is a communication passage, is provided in the first flange portion.

According to a third aspect of the present invention, there is provided an electromagnetic coil device comprising:
The mold material is filled between the winding part and the protrusion,
A communication hole, which is a communication passage, is provided in the winding portion.

According to a fourth aspect of the present invention, there is provided an electromagnetic coil device comprising:
A molding material is filled between the second flange portion and the bobbin receiving surface, and a communication hole serving as a communication passage is provided in the second flange portion.

According to a fifth aspect of the present invention, there is provided an electromagnetic coil device comprising:
A communication groove, which is a communication passage, is provided on a surface of the first flange portion on a side in contact with the coil body.

[0013] The electromagnetic coil device according to the invention of claim 6 is:
A communication groove, which is a communication passage, is provided on a surface of the second flange portion on a side in contact with the coil body.

According to a seventh aspect of the present invention, there is provided an electromagnetic coil device comprising:
A first communication groove, which is a communication passage, is provided on a surface of the first flange portion that is in contact with the coil body, and a first communication groove that is a communication passage is formed on a surface of the second flange portion that is in contact with the coil body. 2
And a connection groove for connecting the first and second communication grooves to each other is provided on a surface of the wrapped portion that contacts the coil body.

The electromagnetic coil device according to the invention of claim 8 is:
The mold material is filled between the winding part and the protrusion,
A groove is formed on at least one of the side surface of the protrusion and the inner surface of the winding portion facing the side surface, the groove extending from the end on the first flange side to the end on the second flange side. Is what is being done.

According to a ninth aspect of the present invention, there is provided an electromagnetic coil device comprising:
A concave portion is provided on the inner wall surface of the iron core, and the concave portion is filled with a molding material.

An electromagnetic coil device according to a tenth aspect of the present invention uses a retaining groove having a V-shaped cross section as the concave portion.

According to an eleventh aspect of the present invention, in the electromagnetic coil device, a plurality of retaining grooves extending in directions intersecting each other when projected onto a plane parallel to the inner wall surface of the iron core are provided on the inner wall surface. .

According to a twelfth aspect of the present invention, there is provided a method of manufacturing an electromagnetic coil device, comprising: setting a core, a bobbin mounted on the core, and a coil body wound around the bobbin in a vacuum chamber; While the inside is evacuated, the uncured mold material is injected from the innermost layer side of the coil body through the communication passage provided in the bobbin, and the uncured mold material is filled between the bobbin and the iron core and between the conductors of the coil body. It includes a step of filling the material and a step of curing the uncured mold material.

According to a thirteenth aspect of the present invention, there is provided a method of manufacturing an electromagnetic coil device, comprising: a tubular winding portion around which a coil body is wound;
A first flange portion provided at one end of the winding portion and provided with a communication hole which is a communication passage communicating with the innermost layer of the coil body; and a first flange portion provided at the other end portion of the winding portion. A non-cured mold material is injected from the communication hole using a bobbin having a second flange portion facing the flange portion.

[0021]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the present invention will be described below with reference to the drawings. Embodiment 1 FIG.

FIG. 1 is a perspective view showing an electromagnetic coil device according to Embodiment 1 of the present invention, FIG. 2 is a sectional view taken along the line II-II of FIG. 1, and FIG. 3 is an enlarged view of a main part of FIG. It is a perspective view and shows what is used for the motor of an elevator hoist in this example.

In the figure, an electromagnetic coil device is an iron core 1.
1. bobbin 12 mounted on iron core 11, coil body 13 wound on bobbin 12, and bobbin 12
Molding material 14 which is filled and hardened between the core 11 and the conductor (for example, enameled wire) of the coil body 13.
have.

The bobbin 12 has a cylindrical winding portion 12a and first opposing first members provided at both ends of the winding portion 12a.
And second flange portions 12b and 12c.
The coil body 13 includes first and second flange portions 12b,
It winds around the winding part 12a between 12c.

The iron core 11 has a bobbin receiving surface 11a facing the second flange portion 12c, a rectangular parallelepiped projection 11b projecting from the bobbin receiving surface 11a and inserted through the inside of the winding portion 12a, and a coil body. 13 has a pair of parallel inner wall surfaces 11c and 11d facing the outer peripheral portion.

As the molding material 14, for example, a thermosetting epoxy resin or the like is used. Mold material 1
4 is also filled between the winding portion 12a and the protruding portion 11b, and between the second flange portion 12c and the bobbin receiving surface 11a.

The winding part 12a, the first flange part 12b, and the second flange part 12c are respectively provided with the coil body 1
Communication holes 15a to 15 which are communication paths communicating with the innermost layer of No. 3
c is provided. The communication holes 15a to 15c serve as flow paths of the uncured (uncured) mold material 14, respectively.

Winding portion 12 facing the side surface of projection 11b
a, the bobbin receiving surface 1 extends from the end on the first flange portion 12b side to the end on the second flange portion 12c side.
A groove portion (notch) 16 having a V-shaped cross section extending in a direction perpendicular to 1a is formed. Inner wall surface 11 of iron core 11
c and 11d are retaining grooves 1 having a V-shaped cross section, which are concave portions.
7 are provided. The molding material 14 is provided with the retaining groove 1.
7 is also filled.

Next, FIG. 4 is an explanatory view showing a state during the manufacture of the electromagnetic coil device of FIG. In the figure, vacuum chamber 2
An exhaust pipe 22 is connected to 1. The exhaust pipe 22 is provided with an exhaust valve 23. In addition, vacuum chamber 2
1, an injection tube 24 is inserted. The tip of the injection tube 24 is connected to the communication hole 15b of the bobbin 12.
The injection pipe 24 is provided with an injection valve 25. An injection device 26 for injecting the uncured mold material 14 into the communication hole 15b is connected to the base end of the injection tube 24.

Next, a method of manufacturing the electromagnetic coil device will be described. First, a coil body 13 having a predetermined number of turns is wound around the bobbin 12 by a winding machine (not shown). Thereafter, the bobbin 12 is detached from the winding machine and is mounted at a predetermined position on the iron core 11. Next, the iron core 11 is set in the vacuum chamber 21. At this time, a flat jig or the like is brought into contact with the side surface of the iron core 11 without the inner wall surfaces 11c and 11d, thereby preventing the uncured mold material 14 from flowing out.

Thereafter, the inside of the vacuum chamber 21 is evacuated through an exhaust pipe 22 by a vacuum pump (not shown). When the inside of the vacuum chamber 21 reaches a predetermined degree of vacuum, the exhaust valve 23 is closed, and the degree of vacuum is maintained. In this state, the injection valve 25 is opened, and the uncured molding material 14 is removed from the injection tube 24.
Through the through hole 15b. The required injection amount of the molding material 14 is obtained in advance by calculation.

After the injection of the molding material 14, the molding material 14 is heated and cured in a heating furnace (not shown). At this time, when the temperature is rapidly increased to the curing temperature of the molding material 14,
Since there is a possibility that peeling or cracking may occur between the resin constituting the molding material 14 and the iron core 11 due to curing shrinkage of the resin constituting the molding material 14, a two-stage temperature increase is desirable.

Further, by subjecting the molding material 14 to a vacuum degassing treatment before the injection, bubbles in the molding material 14 are removed, and the reliability can be improved. Further, in order to improve the fluidity and permeability of the molding material 14, it is also effective to heat the molding material 14 and the iron core 11 in advance. At this time, it is also possible to cause a current to flow through the coil body 13 to cause self-heating.

Here, when manufacturing an electromagnetic coil device having 800 turns, the pressure in the vacuum chamber 21 is increased to 1.33322.
As a result of performing the injection work of the molding material 14 at × 10 ² Pa (1 Torr) and a preheating temperature of about 80 ° C.,
Was filled in the inside and outside of the coil body 13 without any gap.

In such an electromagnetic coil device, the communication holes 15a, 15b, 1 communicate with the innermost layer of the coil body 13.
5c is provided on the bobbin 12, so that the molding material 14 can be spread to every corner of the coil body 13, and the coil body 13 can be firmly fixed to the iron core 11 and generated on the coil body 13. Heat can be released quickly.

The communication hole 1 is formed in the first flange portion 12b.
5b, and the uncured mold material 14 is passed through the communication hole 15b.
Is injected, the molding material 14 can be more reliably filled into the entire coil body 13 with a simple structure. Furthermore, since the communication holes 15a and 15c are also provided in the winding portion 12a and the second flange portion 12c, the entire coil body 13 can be more reliably filled with the molding material 14 with a simple structure.

Further, the groove 1 is formed on the inner surface of the winding portion 12a.
6 is formed, the winding portion 12a and the protrusion 11b
The molding material 14 can be more reliably filled in between. In addition, since the communication holes 15a, 15b, 15c and the grooves 16 are provided in the bobbin 12, the uncured mold material 1 is formed.
4 can be made faster and the working time can be shortened.

Further, since the retaining groove 17 is provided on the inner wall surface 11c of the iron core and the molding material 14 is also filled in the retaining groove 17, it is possible to more reliably prevent the molding material 14 from coming off from the iron core 11. The coil body 13 can be
1 can be firmly fixed. In addition, since the movement of the molding material 14 is suppressed, it is possible to withstand electromagnetic vibration for a long period of time, thereby improving reliability.

In the first embodiment, the retaining groove 17 having a V-shaped cross section is shown as a concave portion. However, the cross-sectional shape of the retaining groove 17 may be, for example, a U-shape. Various changes can be made accordingly. Instead of the retaining groove 17, one or more independent depressions may be provided as recesses on the inner wall surfaces 11c and 11d.

Further, in the first embodiment, the inner wall surface 11
Although a straight retaining groove 17 is provided in each of c and 11d in parallel with each other, a plurality of retaining grooves extending in a direction intersecting each other when projected on a plane parallel to the inner wall surfaces 11c and 11d are formed. , 11d. In this case, it is possible to more reliably prevent the mold material 14 from coming off from the iron core 11 in all directions. Also,
A curved retaining groove may be provided.

Further, in the first embodiment, the winding portion 1
Although the groove 16 is provided on the inner surface of the protrusion 2a, the groove 16 may be provided on the side surface of the protrusion 11b, or may be provided on both the inner surface of the winding portion 12a and the side surface of the protrusion 11b. 1
1b can be more reliably filled with the molding material 14.

Embodiment 2 Next, FIG. 5 is a sectional view of an electromagnetic coil device according to Embodiment 2 of the present invention. In the figure, the bobbin 31 has a tubular winding portion 31a, and first and second flange portions 31b and 31c provided at both ends of the winding portion 31a and facing each other.

The coil body 13 of the first flange portion 31b
The first communication groove 32a, which is a communication path,
A second communication groove 32b, which is a communication passage, is provided on the surface of the second flange portion 31c on the side in contact with the coil body 13. Coil body 1 of winding part 31a
3, the first and second communication grooves 32a, 32
The connection groove 33 which connects b to each other is provided. Other configurations are the same as those of the first embodiment.

In such an electromagnetic coil device, the first and second communication grooves 32 communicated with the innermost layer of the coil body 13.
Since the a, 32b and the connection groove 33 form a flow path of the uncured molding material 14, the molding material 14 can be spread to every corner of the coil body 13, and the coil body 13 is firmly fixed to the iron core 11. And can be fixed to
The heat generated in the coil body 13 can be quickly released.

[0045]

As described above, in the electromagnetic coil device according to the first aspect of the present invention, the bobbin is provided with a communication path communicating with the innermost layer of the coil body and serving as a flow path for the uncured molding material. Therefore, the molding material can be spread to every corner of the coil body.

According to a second aspect of the present invention, there is provided an electromagnetic coil device comprising:
Since the communication hole is provided in the flange portion, the molding material can be more securely filled into the entire coil body with a simple structure.

In the electromagnetic coil device according to the third aspect of the present invention, since the communication hole is provided in the winding portion, the entire coil body can be more reliably filled with the molding material with a simple structure.

According to a fourth aspect of the present invention, there is provided an electromagnetic coil device comprising:
Since the communication hole is provided in the flange portion, the molding material can be more securely filled into the entire coil body with a simple structure.

According to a fifth aspect of the present invention, there is provided an electromagnetic coil device comprising:
Since the communication groove, which is a communication passage, is provided on the surface of the flange portion on the side in contact with the coil body, the molding material can be spread to every corner of the coil body.

According to a sixth aspect of the present invention, there is provided an electromagnetic coil device comprising:
Since the communication groove, which is a communication passage, is provided on the surface of the flange portion on the side in contact with the coil body, the molding material can be spread to every corner of the coil body.

According to a seventh aspect of the present invention, there is provided an electromagnetic coil device comprising:
A first communication groove, which is a communication passage, is provided on a surface of the flange portion on the side contacting the coil body, and a second communication groove, which is a communication passage, is formed on the surface of the second flange portion on the side contacting the coil body. The first and second surfaces are provided on the surface of the wrapped portion that contacts the coil body.
Since the connection grooves connecting the communication grooves are provided, it is possible to more reliably spread the molding material to every corner of the coil body.

In the electromagnetic coil device according to the present invention, at least one of the side surface of the protrusion and the inner surface of the winding portion opposed to the side surface is provided with a second end portion from the end on the first flange portion side. Since the groove portion extending toward the end portion on the flange portion side is formed, the molding material can be more reliably filled between the winding portion and the projection portion.

In the electromagnetic coil device according to the ninth aspect of the present invention, since the concave portion is provided on the inner wall surface of the iron core and the concave portion is filled with the molding material, the mold material can be more reliably prevented from coming off from the iron core. As a result, the coil body can be firmly fixed to the iron core.

In the electromagnetic coil device according to the tenth aspect of the present invention, since the retaining groove having a V-shaped cross section is used as the concave portion, it is possible to more reliably prevent the mold material from coming off from the iron core with a simple structure.

In the electromagnetic coil device according to the eleventh aspect, a plurality of retaining grooves extending in directions intersecting each other when projected on a plane parallel to the inner wall surface of the iron core are provided on the inner wall surface.
In any direction, the mold material can be more reliably prevented from coming off from the iron core.

According to the method of manufacturing the electromagnetic coil device of the twelfth aspect, the uncured molding material is injected from the innermost layer side of the coil main body through the communication path provided in the bobbin. The molding material can be spread to every corner.

In the method of manufacturing an electromagnetic coil device according to the thirteenth aspect, the uncured molding material is injected from the communication hole provided in the first flange portion. The wood can be distributed.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an electromagnetic coil device according to Embodiment 1 of the present invention.

FIG. 2 is a sectional view taken along line II-II in FIG.

FIG. 3 is an enlarged perspective view showing a main part of FIG. 1;

FIG. 4 is an explanatory view showing a state during the manufacturing of the electromagnetic coil device of FIG. 1;

FIG. 5 is a sectional view of an electromagnetic coil device according to Embodiment 2 of the present invention.

FIG. 6 is an explanatory view showing an example of a conventional method of molding an electromagnetic coil device.

FIG. 7 is an explanatory view showing another example of a molding method for a conventional electromagnetic coil device.

[Explanation of symbols]

11 iron core, 11a bobbin receiving surface, 11b protrusion, 1
1c, 11d inner wall surface, 12, 31 bobbin, 12a,
31a winding portion, 12b, 31b first flange portion,
12c, 31c 2nd flange portion, 13 coil body, 14 molding material, 15a, 15b, 15c communication hole (communication passage), 16 groove portion, 17 retaining groove (recess), 21 vacuum tank, 32a first communication groove (Communication passage), 32b Second communication groove (communication passage), 33 Connection groove.

Continued on the front page (72) Inventor Toshio Isooka 2-3-2 Marunouchi, Chiyoda-ku, Tokyo F-term in Mitsubishi Electric Corporation (reference) 5E048 AB06 CB01 5H604 BB01 CC04 CC11 CC20 DB01 PB02 5H615 AA01 BB01 PP01 PP06 PP12 SS15 SS44

Claims (13)

[Claims] 1. A bobbin having a cylindrical winding portion and first and second flange portions provided at both ends of the winding portion and facing each other, between the first and second flange portions. A coil body wound around the winding portion, a bobbin receiving surface facing the second flange portion, a projection projecting from the bobbin receiving surface and inserted through the inside of the winding portion; An iron core having an inner wall surface facing an outer peripheral portion of the main body; and a molding material filled and hardened between the bobbin and the iron core and between conductors of the coil main body, wherein the bobbin includes the coil main body. An electromagnetic coil device, characterized in that a communication passage communicating with the innermost layer and serving as a flow path for the uncured mold material is provided. 2. The electromagnetic coil device according to claim 1, wherein a communication hole serving as a communication passage is provided in the first flange portion. 3. The method according to claim 1, wherein a gap between the winding portion and the projection is filled with a molding material, and the winding portion is provided with a communication hole serving as a communication passage. Or the electromagnetic coil device according to claim 2. 4. A molding material is filled between the second flange portion and the bobbin receiving surface, and a communication hole serving as a communication passage is provided in the second flange portion. The electromagnetic coil device according to any one of claims 1 to 3, wherein 5. The communication device according to claim 1, wherein a communication groove serving as a communication passage is provided on a surface of the first flange portion on a side in contact with the coil body. Electromagnetic coil device. 6. The communication device according to claim 1, wherein a communication groove, which is a communication passage, is provided on a surface of the second flange portion on a side in contact with the coil body. Electromagnetic coil device. 7. A first communication groove, which is a communication passage, is provided on a surface of the first flange portion that is in contact with the coil body, and a surface of the second flange portion that is in contact with the coil body. Is provided with a second communication groove that is a communication passage, and a connection groove that connects the first and second communication grooves to each other is provided on a surface of the winding portion that contacts the coil body. The electromagnetic coil device according to claim 1, wherein: 8. A mold material is filled between the winding portion and the projection, and at least one of a side surface of the projection and an inner surface of the winding portion opposed to the side surface includes:
The electromagnetic coil device according to any one of claims 1 to 7, wherein a groove extending from an end on the first flange side to an end on the second flange side is formed. . 9. The electromagnetic device according to claim 1, wherein a concave portion is provided on an inner wall surface of the iron core, and the mold material is filled also in the concave portion. Coil device. 10. The electromagnetic coil device according to claim 9, wherein the recess is a retaining groove having a V-shaped cross section. 11. The inner wall surface of the iron core is provided with a plurality of retaining grooves extending in directions crossing each other when projected onto a plane parallel to the inner wall surface. Electromagnetic coil device. 12. An iron core, a bobbin mounted on the iron core,
And setting the coil body wound around the bobbin in a vacuum chamber. While the inside of the vacuum chamber is evacuated, through the communication passage provided in the bobbin, the coil body is unloaded from the innermost layer side. Injecting a cured molding material, filling the uncured molding material between the bobbin and the iron core and between the conductors of the coil body, and curing the uncured molding material. A method for manufacturing an electromagnetic coil device. 13. A bobbin, comprising: a tubular winding portion around which a coil body is wound; and a communication hole provided at one end of the winding portion and serving as a communication passage communicating with the innermost layer of the coil body. A first flange portion provided, and a second flange portion provided at the other end portion of the winding portion and facing the first flange portion, and an uncured mold is provided from the communication hole. The method for manufacturing an electromagnetic coil device according to claim 12, wherein a material is injected.