JP2003051414A - Resin mold sealed electromagnetic equipment and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To maintain the air-gap of a resin mold sealed electromagnetic equipment to be constant, when the resin mold is formed. SOLUTION: An insulating material 12 on which a plurality of insulating protrusions 14 are formed is attached to a part of the outer periphery of a laminated electromagnetic steel sheet, which is an iron core that can be divided. A coil 20, made of a spiral steel sheet, is further attached to the outer periphery of the insulation material 12. At this time, a wire of the coil 20 is attached so as to be engaged between the insulating protrusions 14. Consequently, even if a mold resin is injected into a resin mold die, a resin mold can be formed, while maintaining a uniform distance between the wires, since the coil 20 is positioned and fixed by the insulating protrusions 14 of the insulation material 12. Furthermore, the distance between the wires may be maintained, by inserting bending portion formed by bending an insulation paper such as a folding screen between the coil wires.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin mold-sealed electromagnetic device and a method for manufacturing the same, in which variations in voids in the electromagnetic device, for example, gaps between a coil and an iron core are reduced during resin molding.

[0002]

2. Description of the Related Art As a resin mold-sealed electromagnetic device, there is, for example, a resin mold-sealed reactor. Therefore, a resin mold sealing reactor will be described below as an example of the resin mold sealing electromagnetic device.

FIG. 26 shows an outline of the manufacturing process of a conventional resin mold sealing reactor. As shown in FIG. 26, the iron core of the reactor is composed of a laminated electromagnetic steel sheet 10 in which a plurality of electromagnetic steel sheets are laminated.
Is composed of substantially U-shaped laminated electromagnetic steel plate blocks 10a, 10b and rectangular laminated electromagnetic steel plate blocks 10c, 10d.
Tapes 18 as an insulating material are wound around both ends of each of the substantially U-shaped laminated electromagnetic steel plate blocks 10a and 10b.

On the other hand, the coil 20 wound on the outer side of the laminated electromagnetic steel plate 10 which is the iron core is spirally wound by edgewise bending by the bending rollers 90 and 92 while feeding the long steel plate 22 by the feed roller 94. It is manufactured by forming. Further, the surface of the coil 20 made of this steel plate is subjected to electrodeposition insulation coating to manufacture the insulation-coated coil 24.

Next, the rectangular laminated electromagnetic steel plate block 1 is attached to the U-shaped laminated electromagnetic steel plate block 10a on which the tape 18 is wound.
0c and 10d are connected, then the coil 24 is inserted and arranged from the rectangular laminated electromagnetic steel plate block 10c side, and finally the U-shaped laminated electromagnetic steel plate 10b is connected to the rectangular laminated electromagnetic steel plate blocks 10c and 10d. Then, the reactor in which the coil is inserted in the iron core is put into the resin mold, and the resin mold sealing reactor is manufactured by molding resin molding.

Further, in "Resin-molded electromagnetic device" of Japanese Patent Laid-Open No. 7-320951, there is proposed an electromagnetic device manufactured by fixing a coil end to a resin mold and then resin molding. According to the above configuration, when the mold resin is injected during resin molding, it is possible to prevent the coil from being displaced with respect to the iron core.

[0007]

However, for example, as shown in FIG. 27, the insulating material 82 is wound around a part of the outer periphery of the laminated electromagnetic steel sheet 10, and the insulating coated coil 24 is further wound around the outer periphery of the insulating material 82. In such a reactor, for example, after fixing the ends of the coil to the resin mold as proposed in the above publication, as shown in FIG. 28, the mold resin is caused to flow into the resin mold 30 from the inlet 32. In this case (in the direction of the black arrow in the figure), the winding of the coil is pushed and collapsed by the injection pressure of the molding resin, which may result in nonuniform winding intervals. Furthermore, the degree of collapse of the windings differs depending on the pressure at the time of press-fitting the mold resin, and there is a high possibility that the distance between the windings of the coils will differ from reactor to reactor.

As described above, if the distance between the windings of the coil becomes non-uniform, there is a possibility that the products of the resin mold sealing reactor will vary and the performance will deteriorate.

Further, as shown in FIG. 29, the coil of the conventional reactor is an insulation-coated coil 24, and this insulation-coated coil 24 is a coil 20 in which a steel plate is spirally wound.
An insulating coating 26 is formed on the surface of the epoxy resin by epoxy resin, 6,6-nylon or the like.

However, since the epoxy resin or the like used for the insulating coating 26 is a resin having poor thermal conductivity, in the resin mold sealing reactor of the final product,
It is difficult to dissipate the heat generated in the coil during operation to the outside, and the cooling efficiency deteriorates, which may lead to a decrease in product performance.

Therefore, a reactor using a coil 20 in which the coil surface is not coated with insulation is proposed in FIG. As shown in FIG. 30, after the coil 20 made of a steel plate not covered with insulation is fixed to the insulating material 82 with the adhesive 84, the coil 20 is put into the resin mold 30 and resin-molded to manufacture the resin-mold sealing reactor. To be done.

However, in the case of the structure shown in FIG. 30, there is a problem that the production cost is increased because the work of fixing the coil 20 with the adhesive 84 is complicated. Furthermore,
Even if the end portion of the coil 20 can be fixed, when the temperature of the resin mold is raised before the resin mold is injected, the adhesive 84 is softened, and the fixing force of the adhesive 84 is reduced. Coil 2 during injection of mold resin
0 is likely to move, and as a result, the interwinding distance of the coil 20 may be too close to break the insulation.

In addition, even if both ends of the coil 20 are fixed to the resin mold 30 as described above, the coil 2
If the adhesive near the center of 0 is softened, the inter-winding distance of the coil 20 may be too close due to the injection pressure of the molding resin, which may also cause dielectric breakdown.

As described above, during resin molding, there is a problem in that the distance between the windings of the coil becomes non-uniform and, as described below, the gap length between the iron cores becomes non-uniform. It was

That is, in the case of the reactor shown in FIG. 31, in order to increase the magnetic resistance, between the U-shaped laminated electromagnetic steel plate blocks 10a and 10b and the rectangular laminated electromagnetic steel plate 10c, which are iron cores divided into three parts, 16 gaps each
Is provided. Conventionally, an insulating spacer 400 is inserted and arranged in the gap 16, and resin molding is performed in a state where the gap length is secured. here,
The insulating spacer 400 is made of, for example, epoxy resin or 6,6-nylon.

However, when the temperature of the resin mold is raised before the injection of the resin mold, the spacer 400 is also made of an organic material, so that it softens. Therefore, the gap length L changes depending on the pressure at the time of injecting the mold resin, and as a result, the gap length L varies and there is a possibility that the desired magnetic resistance cannot be obtained.

Further, since the gap 16 has a larger change in magnetic flux than other portions, it is easy to generate heat, while the spacer 400 inserted into the gap 16 is made of epoxy resin or the like as described above, Poor thermal conductivity. For this reason, in the conventional case, the heat generated in the vicinity of the gap 16 cannot be efficiently cooled, so that the product performance may be deteriorated.

Therefore, the present invention has been made in view of the above problems, and an object thereof is to prevent variations in voids (gap and coil) of an electromagnetic device during resin molding, and to improve the performance of the electromagnetic device. It is an object of the present invention to provide a resin mold-sealed electromagnetic device that prevents deterioration and a method for manufacturing the same.

[0019]

In order to achieve the above object, a resin-molded electromagnetic device of the present invention and a method of manufacturing the same have the following features.

(1) In an electromagnetic device in which a coil is wound on the outside of an iron core via an insulating material and sealed with a resin mold, the insulating material is an insulating protrusion that keeps the interwinding distance of the coil uniform. It is a resin mold-sealed electromagnetic device.

Since the fixing of the coil winding is strengthened in this manner, there is no risk of the coil winding falling down due to the injection pressure of the molding resin during resin molding. Therefore, product variations can be prevented. Furthermore, since the winding distance between the coils can be kept uniform, it is not necessary to fix an insulating coating on the coil surface as in the conventional case, and the manufacturing process can be simplified. In addition, since the coil made of a steel plate is sealed with, for example, a mold-containing molding resin having high thermal conductivity, heat generated by the coil during the reactor operation can be efficiently released to the outside. As a result, the performance of the reactor can be improved as compared with the conventional case.

(2) In the electromagnetic device described in (1) above, a resin mold sealing in which a plurality of insulating protrusions that are positioned between the windings of the coil are provided on the outer surface of the insulating material. It is an electromagnetic device.

By providing a plurality of insulating protrusions on the outer surface of the insulating material and positioning the coil windings between the insulating protrusions, it is possible to further prevent the coil from collapsing at the time of resin molding, and to perform insulation coating. Since a coil of a non-steel plate can be wound, the manufacturing process can be simplified and the manufacturing cost can be reduced. Further, the heat of the coil can be efficiently radiated to the outside through the mold resin during the operation of the reactor, so that the performance of the reactor can be improved.

(3) In the electromagnetic device described in (1) above, the insulating material is a resin mold-sealed electromagnetic device made of a member that is attached to the iron core and is separable into at least two parts.

As a result, the insulating material with the insulating protrusions can be easily attached to the iron core, the complexity of the work can be eliminated, and as a result, the manufacturing cost can be reduced.

(4) Insulating material dividing step of dividing an insulating material composed of at least two-dividable members on the outer surface of which insulating protrusions are formed to keep the distance between windings of the coil uniform; A step of fitting the insulating material inside the coil so that the insulating protrusion is insulated and positioned,
At least two-dividable iron cores are divided, and an inserting and arranging step of inserting and arranging an insulating material in which a coil is positioned and arranged in each of the divided iron core members, and a resin mold sealing after connecting the divided iron core members. A method of manufacturing a resin mold-sealed electromagnetic device, comprising: a sealing step performed.

By preliminarily positioning and mounting the winding wire of the coil on the insulating projection of the divisible insulating material, a distance between members of each insulating material is opened in the coil extending direction, and the iron core is inserted and arranged between the members. It is possible to manufacture the resin mold sealing reactor in which the coil is fixed even during resin molding.

(5) In an electromagnetic device in which a coil is wound on an outer side of an iron core through an insulating material and sealed with a resin mold, a spacer provided with an insulating protrusion that keeps the winding distance of the coil uniform is provided. The spacer is a resin mold-sealed electromagnetic device arranged so as to sandwich the coil together with the insulating material on the side of the insulating projection forming surface.

By arranging the spacer with the insulating protrusion so as to sandwich the coil together with the insulating material, the insulating protrusion of the spacer can keep the winding interval of the coil uniform even during resin molding. It is possible to prevent variations in the quality of manufactured electromagnetic devices.

(6) In an electromagnetic device in which a coil is wound on the outside of an iron core via an insulating material and sealed with a resin mold using a resin mold, the inner wall of the resin mold has the above-mentioned structure during resin molding. The resin-molded electromagnetic device is provided with a protrusion for maintaining a uniform distance between windings of the coil.

Since the coil can be fixed by the protrusion provided on the inner wall of the resin mold so as to keep the interwinding distance of the coil uniform, the coil winding may be collapsed by the injection pressure of the molding resin. In addition, it is possible to prevent variations between windings and stably manufacture an electromagnetic device of constant quality.

(7) In the electromagnetic device as described in (5) or (6) above, further, a resin mold in which an insulating protrusion is formed on the insulating material to keep the winding distance of the coil uniform. It is a sealed electromagnetic device.

Since the coil winding is fixed from two directions by the insulating protrusion of the insulating material and the insulating protrusion of the spacer or the protrusion of the resin mold, the coil is wound by the injection pressure of the molding resin during resin molding. There is no risk that the line spacing will change.

(8) An electromagnetic device in which a coil is wound on the outside of an iron core via an insulating material and sealed by a resin mold, which is a resin mold-sealed electromagnetic device having a net covering the coil winding.

Since the coil is fixed to the insulating material by the net, there is no risk of the coil moving due to the injection pressure of the molding resin. Furthermore, since it is a net, the mold resin flows, so that the conventional resin mold molding can be performed. Furthermore, since the thing that presses the coil is a net, which is thin, the heat sink can be arranged closer to the coil that generates heat during operation, and thus the heat dissipation efficiency is improved.

(9) In the electromagnetic device described in the above (8), the net is a resin mold-sealed electromagnetic device having a lattice distance through which the mold resin can flow.

If the grid of the net is too clogged, the coil, iron core, etc. covered by the net cannot be sealed with the molding resin. Therefore, the grid distance must be such that the molding resin can flow. Is preferred.

(10) In the electromagnetic device described in (8), the net is a resin mold-sealed electromagnetic device that is a net that can be bonded to the coil.

By using a net that can be adhered to the coil, the coil can be more firmly fixed and the coil winding distance can be kept constant during resin molding.

(11) In the electromagnetic device according to (8), further, the insulating material is a resin mold-sealed electromagnetic device in which an insulating protrusion is formed to keep the interwinding distance of the coil uniform. is there.

Since the coil is held by the net and the windings of the coil are fixed by the insulating protrusions of the insulating material, the windings of the coil do not move during resin molding and the winding interval can be kept uniform.

(12) A plurality of iron cores arranged in parallel with a gap and a coil wound on the outside of the iron core with an insulating material interposed therebetween. In the sealed electromagnetic device, the resin molded mold electromagnetic device is provided with a plurality of protrusions, which are respectively inserted into the gaps between the iron cores, on the inner wall of the resin mold.

Since the resin mold is provided with the protruding portion for keeping the gap constant, the spacer inserted in the gap at the time of resin molding becomes unnecessary, the number of parts can be reduced, and the manufacturing process can be reduced. It can be simplified.

(13) In the electromagnetic device described in (12) above, the projecting portion is a resin mold-sealed electromagnetic device which is inserted into a part of the gap so that a mold resin can flow into the gap.

Since the protrusion is inserted in a part of the gap to secure the gap length, the resin having high thermal conductivity is filled in the gap during resin molding, so that when the electromagnetic device operates. The heat generated near the gap can be efficiently dissipated.

(14) In the electromagnetic device described in (12) or (13) above, depending on the insertion width of the protrusion,
A resin mold-sealed electromagnetic device capable of varying the gap length between the iron cores.

As a result, the mold resin can be filled in the gap while ensuring the desired gap length. Therefore, a desired magnetic resistance can be obtained.

(15) In an electromagnetic device in which a coil is wound around the outer circumference of an iron core and sealed with a resin mold, an insulating paper having a plurality of folding portions formed in a folding screen shape is provided, and each coil is wound between windings. Is a resin mold-sealed electromagnetic device in which the bent portion of the insulating paper is inserted in order to keep the distance between the windings uniform.

By thus inserting the bent portions of the insulating paper between the windings of the coil, the distance between the coil windings is maintained. Even if the coil winding is pushed, there is no danger of falling. Therefore, product variations can be prevented. Further, since the windings of the coil are insulated from each other by the bent portion, the step of forming an insulating coating on the coil surface as in the conventional case is unnecessary, and the manufacturing process can be simplified. In addition, since a plurality of bent portions can be formed by bending the insulating paper in a folding screen shape in accordance with the number of windings of the coil, it is highly versatile.

(16) In the electromagnetic device described in (15) above, the bent portion of the insulating paper inserted between the coil windings is a resin formed by folding the insulating paper into at least two or more folds. It is a mold-sealed electromagnetic device.

By appropriately selecting the number of times of bending in accordance with the desired inter-winding distance of the coil and the thickness of the insulating paper to form the bent portion, and inserting the bent portion between the coil windings,
A predetermined distance between coil windings can be maintained. For example, in the case of an insulating paper having a thickness half the inter-winding distance of the desired coil, a predetermined inter-coil winding distance is maintained by inserting a folded portion between the coil windings. be able to.

(17) In an electromagnetic device in which a coil is wound around the outer periphery of an iron core and sealed with a resin mold, an insulating paper having a plurality of folding portions formed in a folding screen shape is provided, and each coil is wound between windings. In, the bent portion of the insulating paper is inserted,
Further, in the resin-mold-sealed electromagnetic device, a string is inserted and wound in order to keep the distance between the windings uniform during bending of the bent portion inserted between the windings.

For example, when the thickness of the insulating paper is less than half of the inter-coil winding distance, a predetermined inter-coil winding distance can be maintained by inserting a string between the bent portions. it can. In addition, the distance between the coil windings can be secured by mounting the insulating paper on the coil windings and then winding the insulating paper while bending the insulating paper between the coil windings while inserting the cord. Furthermore, since the mold resin with high thermal conductivity can be filled between the folds of the insulating paper, the thermal conductivity is improved compared to the case where the distance between the coil windings is secured only by inserting the insulating paper. The heat generated during operation can be efficiently dissipated, and the performance of electromagnetic equipment is improved.

(18) In the electromagnetic device as set forth in (15) above, the insulating paper is provided with a surface contacting the upper surface of each winding of the coil when the bent portion is inserted between the windings of the coil. The resin-molded electromagnetic device is provided with one or more openings.

Further, since the mold resin having high thermal conductivity enters into the upper surface of the coil winding through the opening of the insulating paper so as to come into direct contact with the upper surface of the coil winding, the heat generated by the coil during the operation of the electromagnetic device directly contacts the mold resin. The heat can be dissipated via the, and as a result, the performance of the electromagnetic device is improved as compared with the above-described configuration.

(19) In the electromagnetic device according to (15) or (18), further, when the bent portion is inserted between the windings of the coil in the insulating paper, each winding of the coil is inserted. The resin-molded electromagnetic device is provided with one or more openings on the surface in contact with the side surface.

Further, the mold resin having high thermal conductivity enters through the opening of the insulating paper so as to come into direct contact with the side surface between the coil windings, so that the heat generated by the coil during operation of the electromagnetic device is in direct contact with the mold. Heat can be dissipated through the resin. As a result, the performance of the electromagnetic device is further improved as compared with the above configuration.

(20) In an electromagnetic device in which a coil is wound around the outer periphery of an iron core and sealed by a resin mold, a resin made of a mold resin and having an insulating material having a plurality of protrusions that can be inserted between respective windings of the coil. It is a mold-sealed electromagnetic device.

Since the protrusion of the insulating material made of the mold resin having high heat conductivity is inserted between the coils, the heat generated by the coil during operation of the electromagnetic device is in contact with the coil while maintaining the distance between the coil windings. Since the heat is efficiently dissipated through the insulating material, the performance of the electromagnetic device is improved.

(21) In an electromagnetic device in which a plurality of coil pieces are conductively connected to the outer circumference of the iron core, wound, and sealed with a resin mold, the coil pieces have a shape close to the outer peripheral shape of the cross section of the iron core. A resin mold-sealed electromagnetic device having an open ring shape in which a part is cut, and formed by winding the open ring ends of adjacent coil pieces attached to the iron core so as to be conductive. Is.

In the case of an integrated type closed magnetic circuit iron core in which one round of the closed magnetic circuit is not interrupted, a coil is conventionally used instead of the iron core (core) of a method of adjusting the inductance by providing a gap like a cut core or an EI core. A method has been adopted in which one end of a wire is fixed and the other end is wound around the outer circumference of a closed magnetic circuit core. However, in the above method, the coil winding work is complicated and the winding work time may be prolonged.

On the other hand, in the case of the above-mentioned electromagnetic device, a plurality of coil pieces can be easily attached to the closed magnetic circuit core, and the coil pieces can be easily attached by connecting one end portions of the adjacent coil pieces so as to be conductive. Can be wound, and thus the working time can be shortened. Further, compared to the case of winding the coil wire, it is easy to keep the distance between the coil windings uniform, so that the performance of the electromagnetic device can be improved.

(22) A step of inserting a plurality of partially opened ring-shaped coil pieces into the outer periphery of the iron core from one direction, and rotating the coil pieces so that the ring-opening ends of adjacent coil pieces are A method for manufacturing a resin mold-sealed electromagnetic device, which comprises a step of joining in a conductive manner.

As described above, it is possible to easily attach a plurality of coil pieces to the outer circumference of the closed magnetic circuit core, and to join the open ring ends of the adjacent coil pieces so that they can be conducted while rotating the coil pieces. Thus, the coil can be mounted in a wound manner on the closed magnetic circuit core. Furthermore, the work for forming the winding shape of the coil is easy and can be performed in a short time. Further, there is an advantage that the distance between the coil windings can be easily kept uniform as compared with the conventional winding method of the coil wire.

(23) In the electromagnetic device described in (21) above, the coil piece has a resin mold-sealed electromagnetic field in which a conductive surface is formed on one end surface and the other end back surface of the ring-opening end. Equipment.

By winding the coil pieces and joining the conductive surfaces of the coil pieces together, a wound coil can be formed.

(24) In the electromagnetic device described in (23), the conductive surface has a thickness that is half the thickness of the coil piece.

For example, in the case where the coil surface is covered with insulation, the above-mentioned configuration makes it possible to form a wound coil in which coil windings are close to each other. As a result, the nonuniformity of the coil winding distance is unlikely to occur during resin molding, and the wound coil can be made more compact. As a result, there is an advantage that the electromagnetic device can be downsized while maintaining the performance.

(25) A step of sequentially inserting partially cut open coil pieces into the iron core from at least two directions, and joining the open ring ends of adjacent coil pieces so that they can be conducted. And a step of performing.

When the coil pieces are rotated as in the above (21) to (24), for example, when the cross-sectional shape of the iron core is rectangular, the distance between the coil and the iron core must be increased. However, with the above configuration, the coil piece is mounted close to the iron core, and the coil piece is not rotated,
The wound coil can be formed by joining the open ends of the coil pieces. Therefore, since the coil and the iron core are close to each other, the performance of the electromagnetic device is further improved.

(26) In the electromagnetic device according to any one of (21), (23) or (24), the coil piece is selected from the group consisting of a U-shape, a U-shape and a C-shape. It is a resin mold-sealed electromagnetic device having a shape.

In the case of improving the performance of the electromagnetic device by bringing the iron core and the coil piece close to each other, for example, when the outer peripheral shape of the iron core is rectangular, a U-shaped coil piece is preferable, and the outer periphery of the iron core in cross section is preferable. When the shape is elliptical or substantially circular, U-shaped or C-shaped coil pieces are preferable. Further, in the case of the C-shaped coil piece, a flexible or thin coil piece is preferable so that it can be easily attached to the iron core.

[0073]

BEST MODE FOR CARRYING OUT THE INVENTION Preferred embodiments of the present invention will be described below. A reactor will be described below as an example of the electromagnetic device, and the same components as those of the conventional reactor described above will be denoted by the same reference numerals and description thereof will be omitted.

Embodiment 1. In FIG. 1, an insulating material 12 having a plurality of insulating protrusions 14 is attached to a part of the outer periphery of a laminated electromagnetic steel plate 10 which is a divisible iron core. Further, the coil 20 made of a spirally wound steel plate formed as described above is attached to the outer periphery of the insulating material 12. At that time, as shown in FIG. 2, the winding of the coil 20 is mounted so as to be fitted between the insulating protrusions 14. Thereby, as shown in FIG. 3, even if the molding resin is injected into the resin molding die 30, the coil is positioned and fixed, so that the resin molding can be performed while keeping the distance between the windings uniform. .

In this embodiment, the insulating material 1
In FIG. 2, the insulating protrusion 14 is provided for each winding of the coil 20, but the present invention is not limited to this, and the insulating protrusion 14 can be positioned as long as the distance between the windings of the coil 20 is kept uniform. It does not have to be provided for each winding.

Further, in the present embodiment, the insulating protrusion 14 may be of a height that can fix a part of the coil 20, and the insulating protrusion 14 has a height that only supports the end portion of the coil from the entire length of the coil. It is preferable that the length is selected according to the injection pressure of the mold resin.

Further, in the present embodiment, as shown in FIG. 4, the insulating material 12 is composed of two members which can be divided into upper and lower parts, that is, an upper insulating material 12b and a lower insulating material 12a.

In the case of assembling to the iron core using the above-mentioned insulating material 12, first, the insulating material 12 is divided into the upper insulating material 12b and the lower insulating material 12a, and the upper insulating material 12b and the lower insulating material 12a are coiled. Insert in 20. Next, between the windings of the coil 20, the upper insulating material 12b and the lower insulating material 12b
The insulating protrusion 14 of a is fitted so as to be positioned. Here, the laminated electromagnetic steel sheet 10 of the present embodiment also includes the substantially U-shaped laminated electromagnetic steel sheet blocks 10a and 10b and the rectangular laminated electromagnetic steel sheet blocks 10c and 10d as described above (FIG. 26). Therefore, the coil 20 is extended to increase the distance between the upper insulating material 12b and the lower insulating material 12a, and the rectangular laminated electromagnetic steel plate block 10c is provided between the upper insulating material 12b and the lower insulating material 12a. After being inserted and arranged, the substantially U-shaped laminated electromagnetic steel plate blocks 10a and 10b and the rectangular laminated electromagnetic steel plate block 10d are connected to manufacture a reactor. After that, this reactor is put into a resin mold made of metal, for example, and a mold resin having a high thermal conductivity containing a filler is sealed therein to manufacture a resin mold sealing reactor.

Since the coil 20 has a spiral winding shape, it can be extended, but preferably the coil winding diameter is
It is easier to assemble the insulating material 12 if the insulating material 12 is slightly longer than the vertically long one.

In the present embodiment, the insulating material 12 is
Although it is composed of two members that can be divided into upper and lower parts, it is not limited to this and may be two members that can be divided into two parts on the right and left. It may consist of a plurality of possible members.

According to the present embodiment, since the winding distance of the coil 20 can be kept uniform even after the resin molding, there is no need to form an insulating coating on the coil 20 as in the conventional case, and the manufacturing process is not required. The process can be simplified. Furthermore, since the heat generated by the coil 20 in the reactor operation can be dissipated through the mold resin having high thermal conductivity, the performance of the reactor can be improved.

Embodiment 2. For this embodiment,
This will be described with reference to FIG. The same components as those in the first embodiment and the conventional resin mold sealing reactor are designated by the same reference numerals and the description thereof will be omitted.

In the first embodiment, the insulating protrusions of the insulating material are fitted between the windings of the coil to perform the insulating positioning, but in the present embodiment, as shown in FIG. The inner wall is provided with a plurality of protrusions 46 for keeping the interwinding distance of the coil 20 uniform.

As described above, before the resin molding, the protrusion 46 of the resin mold 40 is inserted between the windings of the coil to position the winding of the coil 20, so that the molding resin is injected from the injection port 42. However, the pressure does not cause the winding of the coil 20 to collapse, and the distance between the coil windings can be kept uniform even after the resin mold is formed. Therefore, it is not necessary to insulate the coil 20, the manufacturing process can be simplified, the manufacturing cost can be reduced, and the heat generated by the coil 20 during operation of the reactor can be radiated through the mold resin having high thermal conductivity. Therefore, the performance of the reactor can be improved.

In the present embodiment, the insulating material 12 having the insulating protrusions 14 is used, but the present invention is not limited to this, and the protrusions 46 make the windings of the coils uniform according to the injection pressure of the molding resin. If it can be kept at, the insulating material 82 (FIG. 28) having no protrusion described above may be used.

Further, in the present embodiment, the projection 46
Is provided for each winding of the coil 20, but the present invention is not limited to this, and the positioning of the protrusion 46 may be performed not for each winding as long as the distance between the windings of the coil 20 is kept uniform. Well, for example, only in the vicinity of the injection port.

Third Embodiment For this embodiment,
This will be described with reference to FIG. The same components as those of the first and second embodiments and the conventional resin mold sealing reactor are designated by the same reference numerals and the description thereof will be omitted.

In the second embodiment, the protrusion is provided on the inner wall of the resin mold to keep the distance between the windings of the coil constant, but in the present embodiment, as shown in FIG.
Insulating spacer 50 that holds coil 20 together with 2
A plurality of insulating protrusions 52 are provided on the coil 20, and by positioning the insulating protrusions 52 between the windings of the coil 20, the distance between the windings of the coil 20 is kept constant.

The thickness of the portion of the spacer 50 connecting the insulating protrusions 52 is preferably thin. Spacer 5
As the thickness of the connecting portion of 0 is thinner, the fluidity of the injected mold resin is improved and the thickness of the resin mold sealing reactor can be reduced.

As described above, before the resin molding, the insulating protrusion 52 of the spacer 50 is inserted between the windings of the coil to position the winding of the coil 20, so that the injection port 3
Even if the molding resin is injected from 2, there is no fear that the winding of the coil 20 will fall due to the pressure, and the distance between the coil windings can be kept uniform even after the resin molding. Therefore, it is not necessary to insulate the coil 20, the manufacturing process can be simplified, the manufacturing cost can be reduced, and the heat generated by the coil 20 during operation of the reactor can be radiated through the mold resin having high thermal conductivity. Therefore, the performance of the reactor can be improved.

In this embodiment, the insulating material 12 having the insulating protrusions 14 is used. However, the present invention is not limited to this, and the insulating protrusions 52 are used to connect the windings of the coil in accordance with the injection pressure of the molding resin. If it can be kept uniform, the insulating material 82 (FIG. 28) having no protrusion may be used.

In addition, in the present embodiment, the insulating protrusion 52 is provided for each winding of the coil 20, but the present invention is not limited to this. If so, the insulating protrusions 52 may be positioned not only for each winding, but for example, only near the inlet.

Fourth Embodiment For this embodiment,
This will be described with reference to FIGS. Incidentally, the first to third embodiments
The same components as those of the conventional resin mold sealing reactor are designated by the same reference numerals and the description thereof will be omitted.

In this embodiment, as shown in FIG. 7, the winding of the coil 20 is covered with the net 60. The winding of the coil is positioned and fixed by the net 60.

The inter-lattice distance of the net 60 has only to be such that the molding resin can flow, and is preferably substantially the same as the inter-winding distance of the coil 20. Further, it is preferable that the net of the net 60 is covered so as to press the winding of the coil 20. Further, the net 60 is preferably insulative, and for example, a material in which glass fiber is coated with an epoxy resin is particularly preferable. By using the net made of epoxy resin-coated glass fiber, the net 60 is heated when the resin mold 30 is heated before injection of the mold resin.
The epoxy resin on the surface is melted, and as a result, the net 60 adheres to the winding of the coil 20, so that the coil winding can be positioned and fixed more firmly, and thus the distance between the coil windings can be increased even during resin molding. Can be kept uniform. Note that the material of the net 60 is not limited to the above-mentioned material, and any material having a high insulating property may be used.
6-nylon may be used.

The insulating net 60 can satisfactorily insulate the coil 20 and the metal resin mold 30 from each other, and at the same time, prevents variations between windings when the coil 20 is inserted into the laminated electromagnetic steel sheet 10. can do. Further, unlike the conventional case, it is not necessary to bond and fix the coil winding to the insulating material before the resin molding, so that the manufacturing process can be greatly simplified. Further, as shown in FIG. 8, since the winding of the coil 20 is positioned and fixed by the net 60, the mold resin thickness can be made thinner than in the first and second embodiments. As a result, the distance between the heat sink 200 for cooling the resin mold sealing reactor and the coil 20 can be further shortened, so that the heat generated by the coil during operation of the reactor can be cooled more efficiently, and the performance of the reactor can be improved. It can be further improved.

Although the insulating material 82 having no insulating protrusion is used in the present embodiment, the present invention is not limited to this.
The insulating material 12 having the insulating protrusions 14 may be used depending on the injection pressure of the molding resin.

Embodiment 5. For this embodiment,
This will be described with reference to FIG. The same components as those of the first to fourth embodiments and the conventional resin mold sealing reactor are designated by the same reference numerals and the description thereof will be omitted.

As shown in FIG. 9, the laminated electromagnetic steel sheet 10 according to the present embodiment is substantially U-shaped laminated electromagnetic steel sheet block 10a,
10b and rectangular laminated electromagnetic steel plate blocks 10c and 10d
(FIG. 26). Then, a gap 16 is provided between the substantially U-shaped laminated electromagnetic steel plate blocks 10a and 10b and the rectangular laminated electromagnetic steel plate block 10c, and a desired magnetic resistance is obtained by adjusting the gap length L of the gap 16.

In the present embodiment, in order to secure this gap length L during resin molding, the resin molding die 7 is used.
The inner wall of 0 is provided with a plurality of protrusions 76 that are inserted into the gap 16. Further, the protrusion 76 is inserted into a part of the gap 16 so that the mold resin can flow into the gap 16. Further, a desired gap length L can be secured by changing the width of the protrusion 76 or the amount of insertion of the protrusion 76. Furthermore, the gap length L
In order to ensure the above condition more reliably, it is preferable that the protrusions 76 are inserted into the gap 16 from at least two directions.

According to the present embodiment, since it is not necessary to insert the insulating spacer into the gap 16 as in the conventional case, the number of parts can be reduced and the production cost can be reduced. Moreover, since the insulating spacer is made of an organic material as described above, it deforms when the resin mold is heated before injection of the mold resin, and the desired gap length L
However, in the present embodiment, since the protruding portion 76 formed on the inner wall of the metal resin mold 70 that is not deformed even when the resin mold is heated is used, it is possible to prevent Also desired gap length L
Can be secured.

Further, normally, the gap 16 is a portion where the change of the magnetic flux is large and heat is easily generated as compared with the other cases. Therefore, as in this embodiment, by filling the gap 16 with the mold resin containing the filler and having high thermal conductivity,
The heat generated in the gap 16 can be efficiently radiated through the mold resin. Thereby, the performance of the reactor can be improved.

Although the insulating material 82 having no insulating protrusions is used in the present embodiment, the insulating material 82 is not limited to this, and the insulating material 12 with insulating protrusions described in the first embodiment is used.
(FIG. 1) may be used. Further, the spacer 50 (FIG. 6) as shown in the third embodiment and the net 60 (FIG. 7) as shown in the fourth embodiment may be used.

Sixth Embodiment For this embodiment,
This will be described with reference to FIGS. 10 to 14. The first embodiment
5 to 5 and the same configurations as those of the conventional resin mold sealing reactor are denoted by the same reference numerals and the description thereof will be omitted.

FIG. 10 is a cross-sectional view showing a coil 20 wound around the outer periphery of a laminated electromagnetic steel sheet 10 having an iron core having a gap 16, and a vertical cross-sectional view of a portion B surrounded by a wavy line in FIG. Are shown in FIG.

As shown in FIG. 11, in the present embodiment,
The coil 20 is wound around the outer periphery of the laminated electromagnetic steel sheet 10, while the insulating paper 11 has a plurality of folding portions 1 in a folding screen shape.
1a is formed. The bent portion 11a is shown in FIG.
As shown in FIG. 5, the desired coil-to-winding distance, that is, the coil spacing dimension d, is formed so as to hold it even during resin molding.

Therefore, by inserting the bent portion 11a of the insulating paper 11 between the windings of the coil 20, it is assumed that the molding resin is injected from the direction of the black arrow shown in FIG. 14 during resin molding. However, there is no possibility that the winding of the coil 20 will be pushed and fall due to the injection pressure of the molding resin. As a result, it is possible to prevent variations in the interwinding distance of the coil 20 during resin molding. Furthermore, since the winding portions of the coil 20 can be insulated from each other by the bent portion 11a, it is not necessary to forcibly provide the step of forming an insulating coating on the surface of the coil 20 as in the conventional case, and the manufacturing process can be simplified. . In addition, according to the number of windings of the coil 20, a plurality of bent portions 11a can be formed by bending the insulating paper 11 in a folding screen shape. Therefore, the above configuration is versatile.

The insulating paper 11 used in this embodiment is shown in FIG.
As shown in FIG. 2, a resin film 13 having a three-layer structure and excellent in electrical characteristics is replaced with a resin paper 15 having excellent heat resistance.
It is a composite electrical insulating material that is sandwiched between the two and is adhered to each other with an adhesive. More specifically, the resin film 13
Is preferably, for example, a polyester film having excellent electrical characteristics, and the resin paper 15 is, for example, an aromatic polyamide paper (“Nomex Paper” (registered trademark)) having excellent heat resistance characteristics.
(Also referred to as)) is preferable. Further, in the present embodiment, heat-resistant polyamide processed paper for electric insulation (“NTN”, manufactured by Shinko Chemical Industry Co., Ltd.) is used as the insulating paper 11.

Further, in the present embodiment, as shown in FIG. 13, the folded portion 11a is folded in half using the insulating paper 11 having a thickness of ½ of the desired coil spacing dimension d.
Is inserted between the windings of the coil 20, but not limited to this, while the insulating paper 11 covers the upper surface of the coil winding,
In addition, a folded portion 11a formed by folding the insulating paper 11 in at least two folds may be inserted between the coil windings so as to secure a thickness corresponding to the desired coil spacing dimension d.

Seventh Embodiment For this embodiment,
This will be described with reference to FIG. The same components as those of the first to sixth embodiments and the conventional resin mold sealing reactor are designated by the same reference numerals and the description thereof will be omitted.

In the sixth embodiment, only the bent portion 11a (FIG. 11) of the insulating paper 11 is inserted between the windings of the coil 20, but in the present embodiment, as shown in FIG.
A coil 20 is wound around the outer periphery of the laminated electromagnetic steel sheet 10, while the insulating paper 17 has a plurality of folding portions 1 in a folding screen shape.
7a is formed. Then, the bent portion 17a
Is formed to have a size capable of holding a desired coil winding distance during molding. And the coil 20
After the bent portion 17a of the insulating paper 17 is inserted between the windings, the windings are wound while inserting the cord 19 between the bent portions 17a inserted between the windings. The interwinding distance of the coil 20 can be kept uniform.

More specifically, for example, when the thickness of the insulating paper 17 is less than half the winding distance of the coil 20, a dimension obtained by subtracting twice the thickness of the insulating paper 17 from the predetermined winding distance. A predetermined inter-coil winding distance can be maintained by inserting a cord 19 having a diameter of 10 mm between the bent portions 17a.

According to the above-mentioned structure, since the mold resin having high thermal conductivity can be filled between the bent portions 17a of the insulating paper 17 during the bending, the thermal conductivity is improved as compared with the structure of the sixth embodiment, and the electromagnetic wave is improved. The heat generated during the operation of the device can be efficiently dissipated, and the performance of the electromagnetic device is improved.

The insulating paper 17 of the present embodiment may be the insulating paper of the three-layer structure described in the sixth embodiment, for example. Although the material of the string 19 is not limited, it is preferably an insulating material.

Eighth Embodiment For this embodiment,
This will be described with reference to FIG. The same components as those of the first to seventh embodiments and the conventional resin mold sealing reactor are designated by the same reference numerals and the description thereof will be omitted.

In the sixth embodiment, the bent portion 11a formed by folding the insulating paper 11 into a folding screen is inserted between the windings of the coil 20 (FIG. 11), but in the present embodiment,
As shown in FIG. 16, when the bent portion 21 a is inserted between the windings of the coil 20 in the insulating paper 21, the coil 20
One or more openings 23 are provided on the surface in contact with the upper surface of each winding, and one or more openings 25 are further provided on the surface in contact with the side surfaces of each winding.

Therefore, the mold resin having high thermal conductivity enters through the openings 23 and 25 of the insulating paper 21 from the upper surface of the winding of the coil 20 and the side surface between the windings so as to be in direct contact with the coil 20. The heat generated by the coil 20 during the operation of the device can be radiated through the mold resin that is in direct contact with the heat. As a result, the performance of the electromagnetic device is further improved as compared with the above configuration.

Here, the openings 23, 2 of the insulating paper 17 are
In accordance with the distance between the coil windings, 5 may be cut out in advance at positions corresponding to the openings 23 and 25 on one sheet of insulating paper, or the insulating paper may be folded so as to be inserted between the coil windings. The openings 23 and 25 may be provided after the sheet is bent and formed. In addition, the insulating paper 17 is the same as in the sixth embodiment.
You may use the insulating paper of 3 layer structure demonstrated in above.

Ninth Embodiment For this embodiment,
This will be described with reference to FIG. The same components as those of the first to eighth embodiments and the conventional resin mold sealing reactor are designated by the same reference numerals and the description thereof will be omitted.

As shown in FIG. 17, the insulating material 23 of the present embodiment is made of a molding resin used for resin molding, and has a plurality of protrusions 23 that can be inserted between the windings of the coil.
a. The mold resin is preferably a resin having high thermal conductivity, electric insulation, high heat resistance, low thermal expansion, low specific gravity and high effect speed, for example, Al ₂ O ₃ particles,
Unsaturated polyester resins containing any of SiO ₂ particles, glass fibers, etc. are preferred.

According to the above construction, the protrusion 23a of the insulating material 23 made of a mold resin having high heat conductivity is inserted between the coils, so that the distance between the coil windings is maintained and the electromagnetic device is operated during the operation. The heat generated by the coil can be efficiently radiated through the insulating material 23 in contact with the coil. As a result, the performance of the electromagnetic device is improved.

Embodiment 10. FIG. This embodiment will be described with reference to FIGS. 18 to 21 and 23 to 25.

Conventionally, in the case of an uninterrupted integrated magnetic circuit core, which is not an iron core (core) in which a gap is provided to adjust the inductance like a cut core or an EI core, one end of the coil wire is A method of fixing and winding the other end around the closed magnetic circuit core was adopted. Therefore, since the coil wire is only wound, there is a possibility that the coil is pushed during injection of the mold resin during molding and the inter-winding distance becomes uneven. Furthermore, in the case of the above coil wire, the coil winding work is complicated and the winding work time may be prolonged.

Therefore, in the present embodiment, the coil can be easily wound in the closed magnetic circuit core, and
We decided to use coil pieces that can maintain the distance between coil windings.

The coil piece of the present embodiment may have any structure as long as it has an open ring shape that is close to the outer peripheral shape of the cross section of the iron core and is partially cut. When the performance of the electromagnetic device is improved by bringing them close to each other, for example, when the cross-sectional outer peripheral shape of the iron core is rectangular, a U-shaped coil piece 25 as shown in FIG. 18 is preferable and the cross-sectional outer peripheral shape of the iron core is elliptical. Or, in the case of a substantially circular shape, a U-shaped coil piece 31 or C-shaped coil pieces 33, 35
Is preferred. Further, in the case of the C-shaped coil pieces 33, 35, it is preferable that the coil pieces are flexible or have a small thickness so that they can be easily attached to the iron core. This allows
As shown in FIG. 25, the coil pieces can be attached to the iron core while opening both ends of the coil piece back and forth.

The above-mentioned coil piece has, for example, a coil piece 25 shown in FIG.
Conductive surfaces 25a and 25b are formed on one end of (a) and the other end of the back surface (FIG. 18B).

Therefore, as shown in FIG. 19, the conductive surfaces 25a and 25b of the adjacent coil pieces 25 are joined to each other at the portion E in FIG. Shaped coils can be formed.

The coil pieces 25 shown in FIGS.
27 and coil pieces 31, 33, 35 shown in FIGS.
Is formed by punching a steel plate into a desired shape such as a U-shape or by edgewise bending, and the surface of the steel plate is covered with an insulating coating such as enamel. The steel plate surface is exposed only at points 25a and 25b. Here, the conductive surfaces 25a and 25b illustrated in FIG. 18 are the coil pieces 2 that are insulation-coated.
5 may be formed by removing the insulative coating on the corresponding portion, or after masking the portions corresponding to the conductive surfaces 25a and 25b in advance to insulate the coil piece 25, the mask portion is removed. It may be removed and formed.

Next, with reference to FIG. 20, a method of winding a coil around the closed magnetic circuit core 100 in the present embodiment will be described.

First, a plurality of coil pieces having a partially cut open ring shape, for example, a plurality of U-shaped coil pieces 25.
Is inserted into the outer circumference of the iron core from one direction (S100). Next, the coil pieces 25 are rotated by 90 ° (S102), and the ring-opening one ends (F portions) of the adjacent coil pieces 25 are joined by conducting crimping, soldering, laser welding, or the like so that they can be conducted (S104). Then, the joined coil pieces 25
The coil pieces 25 adjacent to each other are rotated by 180 °, and the ring-opening one ends (G portions) of the adjacent coil pieces 25 are also joined so as to be able to conduct (S105), and the above S102 to S105 are repeated to form a closed magnetic circuit. A wound coil is formed on the iron core 100 (S106).

According to the method described above, the plurality of coil pieces 2
5 can be easily attached to the outer circumference of the closed magnetic circuit core 100. Further, by rotating the coil pieces 25 whose shapes are constrained in advance and connecting the open ends of the adjacent coil pieces 25 in a conductive manner, the coil windings are constrained. It is easier to keep the distance between coil windings uniform compared to the method of winding wire. Therefore, the performance of the electromagnetic device can be improved. Furthermore, the above-mentioned coil winding shape forming work can be performed easily and in a short time,
Work efficiency is improved.

Another example of the coil piece 25 is shown in FIG.
Is shown in. As shown in FIG. 21, the conductive surfaces 27 a and 27 b of the coil piece 27 are half the thickness of the coil piece 27. This makes it possible to form a wound coil in which the coil windings are close to each other. Therefore, the distance between coil windings is less likely to be uneven during resin molding, and the wound coil can be made more compact. As a result, there is an advantage that the electromagnetic device can be downsized while maintaining the performance.

Eleventh Embodiment This embodiment will be described with reference to FIG.

In the tenth embodiment, while the coil pieces 25 are rotated, the ends of the adjacent coil pieces 25 are joined in a conductive manner, but as shown in FIG. 19, for example, the iron core has a rectangular cross section. In this case, the distance between the coil and the iron core must be increased.

Therefore, in the coil winding method according to the present embodiment, at least 2 is selected depending on the cross-sectional outer peripheral shape of the iron core.
A plurality of coil pieces each having a shape of one kind or more were prepared and inserted into the iron core from at least two directions, thereby making the coil and the iron core close to each other.

That is, as shown in FIG. 22, two types of coil pieces 29a and 29b having a partially cut open ring shape and having, for example, U-shapes different from each other are formed, and the coil piece 29a is first closed magnetic circuit. The iron piece 100 is inserted from the outside (S200), and the coil piece 29b is further inserted into the closed magnetic circuit core 100.
Of the adjacent coil pieces 29a and 29b are joined to each other (S202). Next, the coil piece 29a is inserted from the inside of the closed magnetic circuit core 100,
The coil piece 29 adjacent to the previously inserted coil piece 29b
The surfaces capable of conducting with a are joined together (S204). Furthermore,
Insert the coil piece 29b from above the closed magnetic circuit core 100,
A coil piece 29 adjacent to the previously inserted coil piece 29a
The conductive surfaces of b are joined together (S206).

According to the above method, since the shape of the coil piece is constrained in advance, it is possible to prevent the coil winding distance from varying due to the pressure when the mold resin is injected during molding. Further, when the cross-sectional outer peripheral shape of the iron core is rectangular, particularly when the core is rectangular, the coil pieces 29a, 29
Since b can be mounted close to the closed magnetic circuit core 100, the performance of the electromagnetic device is further improved.

[0138]

As described above, according to the present invention, at the time of resin molding, it is possible to secure a gap (between the coil windings and the iron core) of the resin-mold sealed electromagnetic device to a desired width. it can.

[Brief description of drawings]

FIG. 1 is a perspective view illustrating an example of a configuration of an insulating material with an insulating protrusion according to the first embodiment of the present invention.

FIG. 2 is a cross-sectional view taken along the line A-A ′ of FIG.

FIG. 3 is a cross-sectional view illustrating a configuration for uniformly maintaining a distance between coil windings during resin molding according to the first embodiment of the present invention.

FIG. 4 is a perspective view illustrating the mounting of the insulating material on the coil according to the first embodiment of the present invention.

FIG. 5 is a cross-sectional view illustrating a configuration for uniformly maintaining a distance between coil windings during resin molding according to the second embodiment of the present invention.

FIG. 6 is a cross-sectional view illustrating a configuration for uniformly maintaining a distance between coil windings during resin molding according to the third embodiment of the present invention.

FIG. 7 is a cross-sectional view illustrating a configuration for uniformly maintaining a distance between coil windings during resin molding according to a fourth embodiment of the present invention.

FIG. 8 is a cross-sectional view illustrating an example of a configuration in which a heat sink is attached to the resin mold sealing reactor shown in the fourth embodiment of the present invention.

FIG. 9 is a sectional view illustrating a configuration for ensuring a gap length during resin molding according to a fifth embodiment of the present invention.

FIG. 10 is a cross-sectional view illustrating the relationship between the iron core and the core according to the sixth embodiment of the present invention.

11 is a vertical sectional view of a portion B surrounded by a wavy line shown in FIG.

FIG. 12 is a cross-sectional view of insulating paper used in Embodiment 6 of the present invention.

FIG. 13 is a cross-sectional view illustrating a configuration according to a sixth embodiment of the present invention that keeps the distance between coil windings uniform.

FIG. 14 is a diagram illustrating that the space between the coil windings is retained even during resin injection in the structure of the sixth embodiment of the present invention.

FIG. 15 is a cross-sectional view illustrating a configuration according to a seventh embodiment of the present invention, which keeps a distance between coil windings uniform.

FIG. 16 is a perspective view illustrating a configuration for uniformly maintaining a distance between coil windings according to an eighth embodiment of the present invention.

FIG. 17 is a perspective view of an insulating material that keeps a distance between coil windings uniform according to a ninth embodiment of the present invention.

FIG. 18 is a perspective view showing the shape of a coil piece shown in Embodiment 10 of the present invention.

FIG. 19 is a perspective view illustrating a structure for uniformly maintaining a distance between coil windings according to a tenth embodiment of the present invention.

FIG. 20 is a diagram illustrating a method of forming a wound coil with respect to the closed magnetic circuit core according to the tenth embodiment of the present invention.

FIG. 21 is a perspective view illustrating the configuration of another example of keeping the distance between coil windings uniform according to the tenth embodiment of the present invention.

FIG. 22 is a diagram illustrating a method of forming a wound coil with respect to the closed magnetic circuit core according to the eleventh embodiment of the present invention.

FIG. 23 is a diagram showing another example of the coil piece according to the tenth embodiment of the present invention.

FIG. 24 is a diagram showing still another example of the coil piece according to the tenth embodiment of the present invention.

FIG. 25 is a diagram illustrating a method of mounting the open annular coil piece of the present invention on the iron core.

FIG. 26 is a diagram illustrating an outline of a manufacturing process of a conventional resin mold sealing reactor.

FIG. 27 is a perspective view for explaining the structure of a conventional insulating material for the iron core and the coil.

FIG. 28 is a cross-sectional view illustrating a situation where the coil winding is pressed by the molding resin during the conventional resin molding.

[Fig. 29] Fig. 29 is a cross-sectional view illustrating the configuration of a conventional reactor in which a coil having an insulating coating is mounted.

FIG. 30 is a cross-sectional view illustrating a configuration in which a coil is adhesively fixed to an insulating material before resin molding in the related art.

FIG. 31 is a cross-sectional view illustrating a configuration in which a spacer is inserted into a gap between conventional iron cores.

[Explanation of symbols]

10 laminated electromagnetic steel sheet, 11 insulating paper, 11a bent portion, 12 insulating material, 14 insulating protrusion, 16 gap, 2
0 coil, 25 coil piece, 25a, 25b conductive surface, 30 resin mold type, 32 inlet, 34 outlet, 100 closed magnetic circuit core.

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI theme code (reference) H01F 41/12 H01F 41/12 D

Claims (26)

[Claims] 1. An electromagnetic device in which a coil is wound on an outer side of an iron core via an insulating material and sealed by a resin mold, wherein the insulating material has an insulating protrusion that keeps a winding distance of the coil uniform. A resin mold-sealed electromagnetic device characterized by the above. 2. The electromagnetic device according to claim 1, wherein the outer surface of the insulating material is provided with a plurality of insulating protrusions positioned between windings of the coil. Mold-sealed electromagnetic equipment. 3. The electromagnetic device according to claim 1, wherein the insulating material is a member that is attached to the iron core and is separable into at least two parts. 4. An insulating material dividing step of dividing an insulating material made of at least a two-dividable member having an insulating protrusion formed on an outer surface thereof to keep a distance between windings of the coil uniform, and between the windings of the coil. An inserting step of inserting the insulating material into the inside of the coil so that the insulating protrusion is insulated and positioned, and an insulating material in which at least a dividable iron core is divided and the coil is positioned and arranged on each of the divided iron core members. A method of manufacturing a resin-molded electromagnetic device, comprising: an insertion-arrangement step of inserting and arranging and a sealing step of connecting each of the divided iron core members and then performing resin-mold sealing. 5. An electromagnetic device in which a coil is wound on an outer side of an iron core via an insulating material and sealed by a resin mold, wherein a spacer provided with an insulating protrusion for maintaining a uniform winding distance of the coil is provided. The resin mold-sealed electromagnetic device, wherein the spacer is arranged so as to sandwich the coil together with the insulating material on the side of the insulating protrusion forming surface. 6. An electromagnetic device in which a coil is wound on an outer side of an iron core via an insulating material and sealed by resin molding using a resin mold, wherein an inner wall of the resin mold has the coil at the time of resin molding. A resin-mold-sealed electromagnetic device, characterized in that it is provided with a protrusion for maintaining a uniform distance between windings. 7. The electromagnetic device according to claim 5, further comprising: an insulating protrusion formed on the insulating material to keep the interwinding distance of the coil uniform. Mold-sealed electromagnetic equipment. 8. An electromagnetic device in which a coil is wound on an outer side of an iron core via an insulating material and sealed by a resin mold, the electromagnetic device having a net covering the coil winding. machine. 9. The electromagnetic device according to claim 8, wherein the net has an interstitial distance that allows the mold resin to flow therethrough. 10. The electromagnetic-molded electromagnetic device according to claim 8, wherein the net is a net that can be bonded to the coil. 11. The electromagnetic device according to claim 8, further comprising: an insulating protrusion formed on the insulating material to keep a distance between windings of the coil uniform. Electromagnetic equipment. 12. A plurality of iron cores arranged in parallel via a gap, and a coil wound on the outside of the iron core via an insulating material, and sealed by resin molding using a resin mold. In an electromagnetic device to be stopped, a resin mold-sealed electromagnetic wave, characterized in that a plurality of protrusions, which are respectively inserted into respective gaps between the iron cores, are provided on an inner wall of the resin mold. machine. 13. The electromagnetic device according to claim 12, wherein the protrusion is inserted into a part of the gap so that mold resin can flow into the gap. . 14. The electromagnetic device according to claim 12 or 13, wherein the gap length between the iron cores is varied by the insertion width of the protrusion. 15. An electromagnetic device in which a coil is wound around an outer circumference of an iron core and sealed by a resin mold, has an insulating paper having a plurality of folding portions formed in a folding screen shape, and between each winding of the coil. Is a resin-molded electromagnetic device in which a bent portion of the insulating paper is inserted in order to keep the distance between windings uniform. 16. The electromagnetic device according to claim 15, wherein the bent portion of the insulating paper inserted between the coil windings is formed by folding the insulating paper into at least two or more folds. Resin mold sealed electromagnetic equipment. 17. An electromagnetic device, in which a coil is wound around an outer periphery of an iron core and sealed by a resin mold, has an insulating paper having a plurality of folding portions formed in a folding screen shape, and between each winding of the coil. The folded part of the insulating paper is inserted, and a string is inserted and wound to keep the distance between the windings uniform during bending of the bent part inserted between the windings. A resin-molded electromagnetic device characterized in that 18. The electromagnetic device according to claim 15, further comprising: a surface of the insulating paper, which is in contact with an upper surface of each winding of the coil when the bent portion is inserted between the windings of the coil.
A resin mold-sealed electromagnetic device having three or more openings. 19. The electromagnetic device according to claim 15 or 18, wherein the insulating paper has a side surface of each winding of the coil when the bent portion is inserted between the windings of the coil. A resin mold-sealed electromagnetic device, characterized in that one or more openings are provided on the contact surface. 20. An electromagnetic device in which a coil is wound around an outer circumference of an iron core and sealed by a resin mold, wherein an insulating material made of a mold resin and having a plurality of protrusions insertable between respective windings of the coil is provided. Characteristic resin-mold sealed electromagnetic equipment. 21. In an electromagnetic device in which a plurality of coil pieces are conductively connected to the outer circumference of an iron core, wound, and sealed by a resin mold, the coil pieces have a shape close to the outer peripheral shape of the cross section of the iron core. A resin mold, which has an open ring shape in which a portion is cut, and is formed in a wound shape by connecting the open ring ends of adjacent coil pieces attached to the iron core in a conductive manner. Sealed electromagnetic equipment. 22. A step of inserting a plurality of coil pieces each having a ring-opening shape that is partially cut into the outer circumference of an iron core from one direction, and conducting the ring-opening one ends of adjacent coil pieces while rotating the coil pieces. And a step of joining them as much as possible. 23. The electromagnetic mold according to claim 21, wherein the coil piece is provided with a conductive surface on one end surface and the other end back surface of the ring-opening end portion. Sealed electromagnetic equipment. 24. The electromagnetic equipment according to claim 23, wherein the conductive surface has a thickness that is half the thickness of the coil piece. 25. A step of sequentially inserting a partially cut ring-shaped coil piece into an iron core from at least two directions, and joining the ring-opening ends of adjacent coil pieces so as to be able to conduct. A method for producing a resin-molded electromagnetic device, comprising: 26. The electromagnetic device according to claim 21, 23, or 24, wherein the coil piece has a shape selected from the group consisting of a U-shape, a U-shape, and a C-shape. A resin mold-sealed electromagnetic device comprising: