JP2005019526A - Method of manufacturing solenoid assembly - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a solenoid assembly which is capable of reducing the solenoid assembly in outer diameter so as to reduce it in size by thinning the winding part and the resin molded part of a bobbin. <P>SOLUTION: The method of manufacturing the solenoid assembly comprises an insertion process of inserting a non-magnetic cylindrical member 22 into the inside of the winding part 21a of the bobbin 21; a winding process of winding an insulating coated wire onto the bobbin 21 where the non-magnetic cylindrical member 22 has been inserted inside so as to form a solenoid 23; and a setting process of setting the bobbin 21 where the non-magnetic cylindrical member 22 is inserted inside, and the solenoid 23 formed by winding the insulating coated wire onto the bobbin 21 to be put in a molding die 50 where a shaft 52 is provided at its center, so as to insert the shaft 52 into the inside of the non-magnetic cylindrical member 22. Moreover, a molding process is provided to fill resin into a gap between the bobbin 21, the solenoid 23 and the molding die 50 to cover the peripheral parts of the bobbin 21 and the solenoid 23 for forming a molded part 24. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method of manufacturing a solenoid assembly used for a solenoid valve or the like.
[0002]
[Prior art]
In solenoid valves used in automobile clutches and brakes, a solenoid coil is wound around a bobbin made of resin material, and its outer periphery is closed by a mold part (housing) also made of resin material. In the bobbin, a core (first yoke) and a yoke (second yoke), which form a magnetic path together through a nonmagnetic cylindrical member (sleeve), are coaxially installed. There is one in which a spool valve is moved by a plunger that is slidably guided and supported (Patent Document 1).
[0003]
According to the solenoid assembly of Patent Document 1, since the core and the yoke are installed via the nonmagnetic cylindrical member provided inside the bobbin, the yoke and the core are required for smooth operation of the plunger. Can be easily and reliably performed.
[0004]
As a method of manufacturing a solenoid assembly having a nonmagnetic cylindrical member on the inner periphery of the bobbin as described above, a manufacturing method including a winding process, a setting process, a molding process, and an insertion process as shown in FIG. 3 is first considered. . First, in the winding process, as shown in FIG. 3 (a), an insulation coated conductor is wound around a winding portion 11a of a synthetic resin bobbin 11 having flanges on both sides to form a solenoid 12. In the next setting step, as shown in FIG. 3B, the bobbin 11 having the solenoid 12 formed in the winding portion 11a is placed in the lower mold 16 of the mold 15 and the shaft 17 provided in the center is formed in the bobbin 11. It is set so as to be inserted around the periphery and covered with the upper mold 18 of the mold 15. In the subsequent molding step, as shown in FIG. 3C, the outer periphery of the set bobbin 11 and solenoid 12 is filled with resin, and the bobbin 11 and solenoid 12 are covered to form a mold part 13. In the final insertion step, as shown in FIG. 3D, the bobbin 11, the solenoid 12, and the mold part 13 formed on the outer periphery thereof are removed from the mold, and the nonmagnetic cylindrical member 14 is placed on the inner periphery of the bobbin 11. insert.
[0005]
[Patent Document 1]
JP-A-11-002354 (paragraph numbers [0012], [0014], FIG. 1)
[0006]
[Problems to be solved by the invention]
However, the above-described method for manufacturing a solenoid assembly has the following problems.
[0007]
In the winding process, the thickness of the winding part 11a of the bobbin 11 cannot be reduced in order to prevent the bobbin 11 from being deformed by the winding force of the insulation coated conductor. Even when the winding portion 11a is made thick, since the synthetic resin has a small rigidity, the inner diameter of the bobbin 11 contracts and changes due to the winding force of the insulating coated conductor, so the inner diameter of the bobbin 11 around which the insulating coated conductor is wound. Considerable dimensional variations occur.
[0008]
As described above, even when the bobbin 11 having a considerable thickness is used for the winding portion 11a of the bobbin 11, a considerable dimensional variation occurs in the inner diameter of the bobbin 11. For this reason, the diameter of the shaft 16 of the mold 15 inserted into the inner periphery of the bobbin 11 in the setting process is the bobbin generated when the mold part 13 is formed when the inner diameter of the bobbin 11 on which the solenoid 12 is formed is the smallest. It is necessary to match so that the releasability by heat shrinkage of the outer diameter portion of 11 can be secured. Therefore, the difference between the diameter of the shaft 16 of the mold 15 and the inner diameter of the bobbin 11 is increased, a gap is generated between the shaft 16 and the inner diameter of the bobbin 11, and the bobbin 11 having the solenoid 12 formed on the mold 15 is set. In this state, the coaxiality between the shaft 16 of the mold 15 and the inner diameter of the winding portion 11a of the bobbin 11 is lowered.
[0009]
Due to the decrease in the coaxiality, the inner periphery of the bobbin 11 on which the solenoid 12 is formed may be set biased to the shaft 16 of the mold 15, and the mold part 13 formed on the outer periphery of the bobbin 11 and the solenoid 12. The thickness is uneven. If the thickness of the mold part 13 is biased, the solenoid 12 may be locally exposed from the mold part 13. To prevent this, the thickness of the mold part 13 must be increased.
[0010]
Thus, in the conventional manufacturing method described above, the thickness of the winding portion 11a of the bobbin 11 and the thickness of the mold portion 13 formed outside the bobbin 11 and the solenoid 12 cannot be reduced. The diameter could not be reduced to reduce the size. The present invention aims to solve such problems.
[0011]
[Means for solving the problems and functions and effects of the invention]
For this purpose, the method of manufacturing a solenoid assembly according to the present invention includes a bobbin in which an insulation-coated conductive wire is wound around a winding portion and an outer peripheral portion is coated with a resin, and the bobbin is inserted into the inner periphery of the winding portion. In a method of manufacturing a solenoid assembly made of a metal nonmagnetic cylindrical member, an insertion step of inserting a nonmagnetic cylindrical member into the inner periphery of the bobbin, and winding an insulation coated conductor around the bobbin with the nonmagnetic cylindrical member inserted into the inner periphery The winding process for forming the solenoid and the shaft is inserted into the inner periphery of the nonmagnetic cylindrical member in the mold provided with the shaft around the bobbin on which the nonmagnetic cylindrical member is inserted and formed on the inner periphery. And the mold part is formed by covering the outer periphery of the bobbin and solenoid with resin by filling the resin between the bobbin and solenoid and the mold. That it is made from the molding process.
[0012]
According to such a method of manufacturing a solenoid assembly, since a metal nonmagnetic cylindrical member is inserted in advance on the inner periphery of the winding portion of the bobbin and then the insulated coated conductor is wound around the bobbin, the bobbin is deformed by the winding force. As a result, variations in the inner diameter are minimal. Thereby, the bobbin which shape | molded the winding part of the bobbin thinly can be used.
[0013]
In addition, since the nonmagnetic cylindrical member integrated with the bobbin around which the insulation-coated conductor is wound has a high rigidity, the inner diameter of the non-magnetic cylindrical member does not substantially deform even by the winding force of the insulation-coated conductor around which the bobbin is wound. The accuracy of is high. Therefore, the gap between the non-magnetic cylindrical member inserted in the inner periphery of the bobbin winding portion in the setting process and the central shaft of the mold can be made extremely small, so that it can be inserted into the mold shaft and the bobbin. The degree of coaxiality between the inner diameters of the nonmagnetic cylindrical members is increased.
[0014]
As described above, since the coaxiality between the inner diameter and the shaft of the nonmagnetic cylindrical member is high, between the outer periphery of the bobbin in which the nonmagnetic cylindrical member is inserted and the solenoid wound around the bobbin and the inner periphery of the mold die. There is no eccentricity, and the thickness of the mold part is uniform, so that the possibility of the solenoid being locally exposed is reduced. As described above, the mold part formed on the outer periphery of the bobbin and the solenoid in the mold die is less likely to be exposed locally, so that the mold part of the conventional solenoid assembly manufacturing method shown in FIG. Can be thin.
[0015]
Therefore, according to the method for manufacturing a solenoid assembly according to the present invention, a thin bobbin winding part can be used, and the mold part provided on the outer periphery of the bobbin and the solenoid can be thinned. The outer diameter of the solenoid assembly can be reduced to reduce the size.
[0016]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, a method for manufacturing a solenoid assembly according to the present invention will be described with reference to FIG. This method for manufacturing a solenoid assembly is composed of four steps: an insertion step, a winding step, a setting step, and a molding step.
[0017]
FIG. 1A is a diagram illustrating an insertion process in which a metallic nonmagnetic cylindrical member 22 is inserted into the inner periphery of the bobbin 21. The bobbin 21 is pre-molded with a synthetic resin and includes flanges 21b and 21c at both ends of a cylindrical winding portion 21a. The inner diameter of the winding portion 21a is the same as the outer diameter of the nonmagnetic cylindrical member 22. It is sufficient if they are substantially the same. Since the bobbin 21 is reinforced by inserting the nonmagnetic cylindrical member 22 on the inner periphery, the bobbin 21 may be thinner than the bobbin 11 of the conventional method for manufacturing a solenoid assembly shown in FIG. The nonmagnetic cylindrical member 22 is made of a metal such as austenitic stainless steel or brass.
[0018]
FIG. 1B is a diagram illustrating a winding process in which a solenoid 23 is formed by winding an insulating coated wire around a winding portion 21a of a bobbin 21 in which a nonmagnetic cylindrical member 22 is inserted on the inner periphery. The bobbin 21 is wound around the winding portion 21a with an insulating coated conductor. However, since the metal nonmagnetic cylindrical member 22 having a rigidity higher than that of the synthetic resin is inserted into the inner periphery of the winding portion 21a, the bobbin 21 is wound. Even if the winding force is applied to the wire portion 21a, the wire portion 21a is not further deformed as long as its inner periphery comes into contact with the outer periphery of the nonmagnetic cylindrical member 22. Further, since the nonmagnetic cylindrical member 22 is inserted in the inner periphery of the winding portion 21a, the winding portion 21a is attached to the inner peripheral nonmagnetic cylindrical member 22 by a winding force that winds the insulating coated conductor around the winding portion 21a. The bobbin 21 abuts and is fixed to the nonmagnetic cylindrical member 22 when the inner periphery of the winding portion 21 a contacts the outer periphery of the nonmagnetic cylindrical member 22. The non-magnetic cylindrical member 22 may be lightly press-fitted so that the outer periphery is in contact with the inner periphery of the winding portion 21a of the bobbin 21, and in that case, the bobbin 21 is not deformed and contracted by winding of the insulating coated conductor. The inner circumference of the winding portion 21 a is abutted and fixed to the outer circumference of the nonmagnetic cylindrical member 22. Note that the insulation-coated conductive wire is, for example, a copper wire coated with enamel.
[0019]
FIG. 1C is a diagram showing a setting process in which the bobbin 21 in which the solenoid 23 is formed in the winding portion 21 a and the nonmagnetic cylindrical member 22 inserted in the inner periphery thereof are set in the mold 50. The mold 50 includes a lower mold 51 and an upper mold 53, and a shaft 52 inserted into the nonmagnetic cylindrical member 22 is formed coaxially with a molding hole of the lower mold 51. The shaft 52 of the lower mold 51 of the mold 50 is inserted into the inner periphery of the nonmagnetic cylindrical member 22 inserted in the inner periphery of the bobbin 21 and pressed by the upper mold 53. Since the non-magnetic cylindrical member 22 is made of metal, it is not substantially deformed by the winding force when the insulating coating conductor is wound around the winding portion 21a of the bobbin 21 in the above-described winding process, so that the accuracy of the inner diameter is high. It becomes. Accordingly, the gap between the inner diameter of the nonmagnetic cylindrical member 22 and the shaft 52 is extremely small, and the coaxiality between the inner diameter of the nonmagnetic cylindrical member 22 and the shaft 52 is increased, so that the bobbin 21 on which the solenoid 23 is formed is The coaxiality with respect to the shaft 52 in the mold 50 is increased, and the gap between the outer periphery of the bobbin 21 and the solenoid 23 and the inner periphery of the lower mold 51 is also substantially constant.
[0020]
FIG. 1D is a diagram illustrating a molding process in which the outer periphery of the bobbin 21 and the solenoid 23 set in the mold 50 is covered with a synthetic resin to form the mold portion 24. As described above, the bobbin 21 and the solenoid 22 are set in the mold 50 so that the gap between the outer periphery thereof and the inner periphery of the lower mold 51 is substantially constant. Even if the mold part 24 formed on the outer periphery of the bobbin 21 and the solenoid 23 is thinner than the mold part 13 of the conventional method for manufacturing a solenoid assembly shown in FIG. 3, the solenoid 23 is not exposed.
[0021]
As described above, according to the method of manufacturing the solenoid assembly shown in FIG. 1, the thinned winding portion 21 a of the bobbin 21 can be used, and the mold portion 24 provided on the outer periphery of the bobbin 21 and the solenoid 23 is thinned. Therefore, the outer diameter of the solenoid assembly can be made smaller and smaller than the conventional manufacturing method shown in FIG.
[0022]
Next, a solenoid valve using the solenoid assembly 20 according to the manufacturing method of the present invention will be described with reference to FIG. This electromagnetic valve includes an electromagnetic drive unit 30 and a valve unit 40.
[0023]
The electromagnetic drive unit 30 includes a stator 31 and a plunger 35. The stator 31 includes the solenoid assembly 20 manufactured as described above, and a yoke 33 and a core 34 that are coaxially connected to each other through a metallic non-magnetic cylindrical material 22 therein. The plunger 35 is entirely made of a magnetic material, is coated with a nonmagnetic material, and is slidably supported by the inner hole of the yoke 33 of the stator 31. The cover 36 provided outside the stator 31 has a bottomed cylindrical shape made of a magnetic material and covers the yoke 33 and the core 34.
[0024]
The valve portion 40 includes a sleeve 42 that is caulked and fixed to the stator 31 by a cover 36, and a spool 41 that is guided and supported coaxially and slidably on the sleeve 42. In the spool 41, a shaft portion 41 a that protrudes from the tip of the spool 41 passes through the center of the core 34 and is in contact with the valve portion side end surface of the plunger 35.
[0025]
The plunger 35 has a retracted position where the one end surface 35a on the inner bottom surface side of the cover 36 contacts the inner bottom surface of the cover 36 (see the lower half of FIG. 2), and the other end surface 35b on the valve portion side is a washer in the core 34. It can move between the advance positions (see the upper half of FIG. 2) that abut via 37.
[0026]
When the solenoid valve is in an inoperative state, the spool 41 is urged toward the electromagnetic drive unit 30 by a spring (not shown) at the rear end of the sleeve 42, and the plunger 35 abutted against the shaft portion 41a of the spool 41 is The one end surface 35a is in a retracted position (described above) in contact with the inner bottom surface of the cover 36. In the operating state in which the solenoid 23 is energized, the yoke 33, the core 34, and the cover 36 are magnetized according to the energization amount, the plunger 35 is pulled toward the core 34, and the spool 41 that is in contact with the plunger 35 is removed. The valve is actuated by moving it against the spring.
[Brief description of the drawings]
FIG. 1 is a view showing a method of manufacturing a solenoid assembly according to the present invention.
FIG. 2 is a longitudinal sectional view showing a part of a solenoid valve to which a solenoid assembly according to the present invention is applied.
FIG. 3 is a view showing a conventional method for manufacturing a solenoid assembly.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 20 ... Solenoid assembly, 21 ... Bobbin, 21a ... Winding part, 22 ... Nonmagnetic cylindrical member, 23 ... Solenoid, 24 ... Mold part, 50 ... Mold die, 51 ... Lower die, 52 ... Shaft

Claims (1)

A method for manufacturing a solenoid assembly comprising a bobbin in which an insulation-coated conductive wire is wound around a winding portion and an outer peripheral portion is coated with a resin, and a metal nonmagnetic cylindrical member inserted into the inner periphery of the winding portion of the bobbin In
An insertion step of inserting the non-magnetic cylindrical member into the inner periphery of the bobbin;
A winding step in which a solenoid is formed by winding the insulation coated conductor around the bobbin in which the nonmagnetic cylindrical member is inserted on an inner periphery;
The non-magnetic cylindrical member is inserted into the inner periphery and the solenoid is formed. The bobbin is formed so that the shaft is inserted into the inner periphery of the non-magnetic cylindrical member. A set process;
A method of manufacturing a solenoid assembly, comprising: a molding step in which a resin is filled between the bobbin and the solenoid and the mold to cover the outer periphery of the bobbin and the solenoid to form a mold part.

Images