JP2005135976A - Electromagnetic device, manufacturing method thereof and discharge lamp equipment and lighting apparatus using the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing an electromagnetic device, in which an opening and a boundary part causing partial discharge do not exist in a resin material, in which, at least an outer periphery on the high-voltage side in a transformer compact, is wrapped. <P>SOLUTION: The low-voltage side of the transformer compact is held with a holding part by using a resin forming metallic mold having a cavity, into which the transformer compact is inserted and melting resin is implanted, the holder holding the low-voltage side of the transformer compact, a low-voltage side gate arranged at the low-voltage side of the transformer compact, and a high-voltage side gate arranged on the high-voltage side of the transformer compact. Melting resin which is melted is implanted in the cavity from the high-voltage side gate. Molten resin is injected from the low-voltage side gate into the cavity at prescribed timing, when the molten resin externally wraps the high voltage of the transformer compact. The whole transformer compact is sealed with a resin material. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to an electromagnetic device manufacturing method, an electromagnetic device, a discharge lamp device using the same, and a lighting fixture.

  Conventionally, as an example of an electromagnetic device, a bobbin winding coil has been known, and the illustration is omitted, but this bobbin winding coil is attached to a body portion of a resin bobbin in which a core iron core is fitted at a central position. A coil wire is wound, and the outer periphery of the wound coil wire is sealed with an insulating resin. A resin sealing method for a bobbin-wound coil is disclosed in Japanese Patent No. 3358219 (Patent Document 1).

  In this resin sealing method, first, the iron core protrudes from one end of the bobbin, and a shaft hole concentric with the iron core is provided on the other end surface of the bobbin, and a support pin can be inserted into this shaft hole. Done. Subsequently, the bobbin around which the coil wire is wound is positioned and held in the cavity of the resin molding die by supporting the protruding portion of the iron core and the support pin, and then molten resin is injected into the cavity to remove the coil wire from the coil wire. When the periphery is filled and sealed with a resin material, the bobbin-wound coil is completed.

Although not shown, a casting mold comprising a spacer for positioning and fixing the coil body in the cavity is disclosed in Japanese Patent Laid-Open No. 6-238680 (Patent Document 2). . That is, in this casting mold, a coil body wound with a coil wire is fixed by a spacer, and an insulating resin is filled around the outer periphery of the coil body to form an insert molded body. A recess having a predetermined depth used for adjusting the protruding length of the spacer in the cavity is provided at a predetermined position of the mold body.
Japanese Patent No. 3358219 JP-A-6-238680

  By the way, according to the resin sealing method of the bobbin winding coil disclosed in Patent Document 1, it is possible to position and hold the bobbin on which the coil wire has been wound in the cavity of the resin molding die. However, on the high voltage part side of the bobbin-wound coil after sealing with the resin material, a part of the bobbin-wound coil exposed from the insert molded body or an opening formed by a support pin that penetrates the insert molded body Partial discharge may occur at the portion, and this partial discharge may lead to dielectric breakdown of the insert molded body.

  Further, when forming the insert body of the coil body using the casting mold disclosed in Patent Document 2, the protrusion length in the cavity of the spacer for fixing the coil body can be adjusted. The advantage that the coil body can be held at a predetermined position in the cavity is ensured. However, when an insert molded body is formed using this casting mold, insert molding made of an insulating resin filled in the outer periphery of the coil body 51 is shown in FIG. For each predetermined position of the body 52, an opening 53 is formed by a spacer.

  Normally, these openings 53 are refilled with insulating resin (not shown), but even in this case, there is a gap between each opening 53 and the refilled insulating resin. A boundary portion 54 is formed. In such a boundary portion 54, the insulation strength may be weak, and partial discharge is likely to occur, which may cause dielectric breakdown.

  Thus, by sealing the resin while holding the coil, an opening and a boundary portion remain in the coil after sealing. This is particularly a problem on the high voltage side of the coil.

  The present invention was devised in view of the above problems, and a resin material enclosing at least the outer periphery on the high voltage portion side of a transformer molded body formed by sealing a transformer structure with an insulating material, Equipped with an electromagnetic device having no opening or boundary that causes discharge, a resin molding die capable of forming a resin material without an opening or boundary, and a resin material without an opening or boundary An object of the present invention is to provide a manufacturing method for manufacturing an electromagnetic device.

  In the method of manufacturing an electromagnetic device according to the present invention, a transformer molded body in which an outer periphery of a transformer structure having a core and a coil winding wound on a side surface of the core is sealed with an insulating material is inserted. A cavity into which molten resin is injected, a holding part for holding the low voltage part side of the transformer molded body, a low voltage part side gate provided at one or more locations on the low voltage part side of the transformer molded body, A low-voltage part side of the transformer molded body using the mold for resin molding having at least one high-voltage part-side gate provided on the high-voltage part side of the transformer molded body, The molten resin is then injected into the cavity from the high voltage portion side gate, and then the molten resin is injected from the low voltage portion side gate at a predetermined timing when the molten resin encloses the high voltage portion of the transformer molded body. The cavity Was injected into the sealed across the transformer molded body of a resin material.

  In the method for manufacturing an electromagnetic device according to the present embodiment, no opening or boundary portion is generated at least on the high voltage portion side of the resin material enclosing the outer periphery of the transformer molded body. In addition, a thin portion due to misalignment of the transformer molded body is not formed. Therefore, there is no possibility that partial discharge due to the presence of an opening, a boundary portion, a thin portion, etc. occurs, and an appropriate and stable dielectric breakdown strength can be ensured.

(Embodiment 1)
The electromagnetic device 1 according to the present embodiment is used to generate a high voltage pulse voltage necessary for a high pressure discharge lamp starting device or the like, and is called a pulse transformer. First, as shown in FIG. 1, a secondary coil winding 3 is wound on the side surface of a rod-shaped ferrite core 2, and a primary coil winding 4 is further wound thereon to form a transformer structure 5. Get. Next, as shown in FIGS. 2 and 3, a transformer molded body 10 is obtained by molding the outer periphery of the transformer structure 5 with an insulating material 6 by injection molding or transfer molding. Here, a plurality of grooves 9 are formed in parallel on the outer peripheral surface of the transformer molded body 10 in order to extend the creeping distance and enhance the insulation function. A pair of lead terminals 7 a, 7 b, 8 a, and 8 b are disposed on the outer peripheral surface of the transformer molded body 10. At this time, although not shown, the terminals 3a and 3b of the secondary coil winding 3 are connected to the lead terminals 7a and 7b, respectively, and the primary coil is connected to each of the lead terminals 8a and 8b. Terminals 4a and 4b of the winding 4 are connected to each other. Thereafter, as shown in FIG. 4, the electromagnetic device 1 is obtained by further sealing the outer periphery of the transformer molded body 10 with a resin material 11.

  A method for manufacturing the electromagnetic device 1 from the transformer molded body 10 in this embodiment will be described below. First, examples of the resin material 11 include thermoplastic resins such as polyetherimide, syndiotactic polystyrene, polyamide, liquid crystal polymer, and polyphenylene sulfide, and thermosetting resins such as epoxy resin and unsaturated polyester. Further, in order to seal the transformer molded body 10 with the resin material 11, a resin molding die 20 as shown in FIG. 5 is used. That is, the resin molding die 20 includes an upper die 21 and a lower die 22 that are divided into two parts by a parting line P, and an upper die 21 and a lower die that are integrally connected by the parting line P. Inside the mold 22 is provided a cavity 23 having a predetermined shape in which the transformer molded body 10 is inserted and held. Here, the resin molding die 20 includes a resin material injection port 34, a first sprue 24, a main runner 25, a low voltage portion side second sprue 26, a high voltage portion side second sprue 27, and a low voltage portion side runner 28. The high voltage part side runner 29, the low voltage part side gate 30, and the high voltage part side gate 31 are provided. Moreover, the holding parts 32 and 33 which hold | maintain the low voltage part 12 side of the transformer molded object 10 are provided.

  Next, based on FIGS. 6-9, the manufacturing procedure at the time of manufacturing the electromagnetic device 1 using the metal mold | die 20 for resin molding is demonstrated.

  As shown in FIG. 6, the transformer molded body 10 is inserted and set in the cavity 23 of the resin molding die 20. At this time, the transformer molded body 10 is held by the holding portions 32 and 33, and the holding portion 32 has a clearance A.

  Here, the pressure of the molten resin G injected into the cavity 23 from the gates 30 and 31 divided in two by the parting line P is maintained by the transformer molding by holding the transformer molded body 10 at the upper and lower intermediate positions in the cavity 23. It is made substantially equal in the direction facing each other through the body 10. Prior to insertion into the cavity 23, the transformer molded body 10 is preheated at a temperature equal to or lower than the melting point of the molten resin G.

  Further, as shown in FIG. 7, the molten resin G is injected from the resin material injection port 34 of the resin molding die 20. The molten resin G passes through the first sprue 24 and the main runner 25, and is first filled into the cavity 23 through the high voltage portion side second sprue 27, the high voltage portion side runner 29, and the high voltage portion side gate 31. . At that time, the transformer molded body 10 is moved by the pressure of the molten resin G, and the transformer molded body 10 is held in a state where the clearance A in the holding portion 32 is eliminated.

  Thereafter, the molten resin G gradually spreads into the space of the cavity 23 and is filled around the high voltage portion of the transformer molded body 10 as shown in FIG. When the molten resin G wraps around the outer periphery of the high voltage portion of the transformer molded body 10, the molten resin G passes through the low voltage portion side second sprue 26, the low voltage portion side runner 28, and the low voltage portion side gate 30. Then, the cavity 23 starts to be filled. Here, the flow length of the molten resin G from the resin material injection port 34 to the low voltage part side gate 30 is made longer than the flow length of the molten resin G from the resin material injection port 34 to the high voltage part side gate 31. Yes. As a result, the timing of injecting the molten resin G from the low voltage portion side gate 30 is delayed. Further, since two gates of the low voltage part side gate 30 and the high voltage part side gate 31 are provided as the gates for injecting the molten resin G into the cavity 23, for example, only from the high voltage part side gate 31 The resin pressure applied to the high voltage portion of the transformer molded body 10 is reduced as compared with the case where molten resin is injected.

  Then, as shown in FIG. 9, the molten resin G is completely filled in the cavity 23. Here, the molten resin G filled from the two directions of the high-voltage part side gate 31 and the low-voltage part side gate 30 is associated in the cavity 23, and this meeting part 14 is composed of the high-voltage part side gate 31 and the low-voltage part gate 31. Since one of the molten resins G filled from the two directions of the side gate 30 is in the shape of the other molten resin, the creepage distance is increased, and as a result, the insulation performance can be further improved.

  In this manner, the outer periphery of the transformer molded body 10 is wrapped with the molten resin G without forming an opening or a boundary portion at least on the outer periphery on the high voltage portion side.

  Further, after the molten resin G filled by injection molding of the thermosetting insulating resin is solidified, the electromagnetic device 1 wrapped with the resin material 11 is taken out from the cavity 23 of the resin molding die 20. The electromagnetic device of this embodiment is manufactured by the above.

  In the method for manufacturing an electromagnetic device according to the present embodiment, no opening or boundary portion is generated at least on the high voltage portion side of the resin material enclosing the outer periphery of the transformer molded body. In addition, a thin portion due to misalignment of the transformer molded body is not formed. Therefore, there is no possibility that partial discharge due to the presence of an opening, a boundary portion, a thin portion, etc. occurs, and an appropriate and stable dielectric breakdown strength can be ensured.

  Moreover, since the pressure of the molten resin injected into the cavity is substantially equal in the direction facing the transformer molded body, the transformer molded body is less likely to be displaced in the cavity. For this reason, it can prevent that the thin part which causes a partial discharge is formed in the electromagnetic device obtained. Further, since the transformer molded body inserted into the cavity is preheated at a temperature below the melting point of the resin material, the fluidity of the molten resin in the cavity is improved, and the pressure of the molten resin applied to the transformer molded body is reduced. . For this reason, it is possible to make it difficult for the transformer molded body to be displaced. Furthermore, because the transformer molded body is positioned in the holding part by the pressure of the molten resin injected from the high-voltage part side gate, the transformer molded body is held even when the setting accuracy of the transformer molded body to the resin mold is rough. It is possible to accurately position the part. In addition, by making the flow length from the resin material supply part that supplies molten resin to the low voltage part side gate longer than the flow length from the resin material supply part to the high voltage part side gate, there is no special equipment. The timing of the molten resin injection from the low-voltage part side gate can be delayed from the timing of the molten resin injection from the high-voltage part side gate, and further, thereby holding the high voltage part side of the transformer molded body. Even if not, the molten resin filled in the outer periphery of the high-voltage part serves to hold the high-voltage part side of the transformer molded body, and it is possible to further prevent the displacement of the transformer molded body due to the injection of the molten resin. .

  Further, in the electromagnetic device manufactured by the manufacturing method of the present embodiment, the insert molded body wraps the transformer structure without an opening or a boundary portion. Is not formed. Therefore, there is no possibility that partial discharge occurs, and an effect of ensuring appropriate dielectric breakdown strength can be obtained. In addition, the discharge lamp device including the electromagnetic device is less likely to cause dielectric breakdown even when a high voltage is generated when the discharge lamp is turned on, and has the effect of being stably lit without being turned off. can get. Furthermore, the lighting fixture provided with the said discharge lamp apparatus can obtain the effect that a discharge lamp is lighted stably without becoming non-lighting and reliability is improved.

(Embodiment 2)
The method for manufacturing the electromagnetic device of the second embodiment is substantially the same as that of the first embodiment, but the configuration and the molding method of the resin molding die are partially different, so this point will be described.

  As shown in FIG. 10, the resin molding die 40 according to the present embodiment includes an upper die 41 and a lower die 42 that are divided into two by a parting line P, and the upper die 41 has a low voltage. A part-side resin material inlet 43 and a high-voltage part-side resin material inlet 44 are provided, and a resin pressure sensor 50 is disposed in the lower mold 42.

  The molten resin G injected from the high voltage part side resin material injection port 44 is a high voltage part side first sprue 46, a high voltage part side main runner 48, a high voltage part side second sprue 27, a high voltage part side runner 29, It is injected into the cavity 23 through the high voltage side gate 31. The molten resin G injected from the low-voltage part side resin material injection port 43 includes the low-voltage part side first sprue 45, the low-voltage part side main runner 47, the low-voltage part side second sprue 26, and the low-voltage part side runner. 28, injected into the cavity 23 through the gate 30 on the low voltage side. In this way, the molten resin G injected from the high voltage part side gate 31 and the low voltage part side gate 30 can be controlled independently.

  Further, by measuring the pressure of the molten resin G injected from the high voltage portion side gate 31 using the resin pressure sensor 50, the timing for injecting the molten resin from the low voltage portion side gate 30 can be determined. . This is because there is a correlation between the pressure of the molten resin G in the cavity 23 and the filling state thereof, and the elapsed time after the injection of the molten resin G is started and the molten resin G in the cavity 23. This is because there is also a correlation with the pressure. Therefore, in the method of manufacturing the electromagnetic device according to the present embodiment, as shown in FIG. 11 showing the relationship between the resin pressure and the elapsed time, the time when the pressure of the molten resin G in the cavity 23 reaches a set value. The timing for injecting the molten resin from the low voltage side gate 30 is set. By injecting the molten resin at such timing, the boundary surface of the molten resin G is not formed in the outer periphery on the high voltage portion side of the transformer molded body 10, and a sufficient resin thickness is secured. Can do. Thereby, the insulation strength of the electromagnetic device can be ensured. That is, when the molten resin is injected from the low voltage portion side gate 30 at an early timing, the molten resin G is melted from the low voltage portion side while the outer periphery of the transformer molded body 10 on the high voltage portion side is not completely wrapped. Since the resin is injected, a boundary surface of the molten resin G is formed in the outer periphery on the high voltage part side of the transformer molded body 10. On the contrary, if the timing of injecting the molten resin G from the low voltage portion side gate 30 is late, the resin pressure on the high voltage portion side becomes too high, and the transformer molded body 10 may be misaligned. The resin thickness cannot be ensured.

  In the electromagnetic device manufacturing method according to the present embodiment, the molten resin injected from the high-voltage part side gate and the molten resin injected from the low-voltage part side gate are controlled independently. Can be controlled individually with high accuracy, and the positioning accuracy of the transformer molded body can be improved.

  In addition, the predetermined timing when the molten resin encloses the high voltage portion of the transformer molded body is the time when the resin pressure in the predetermined portion in the cavity reaches a set value, so the molten resin is injected from the low voltage portion side gate. It becomes easy to detect the timing, the molten resin can be reliably injected from the low voltage portion side gate, and the transformer molded body can be accurately positioned on the holding portion.

It is a perspective view showing the appearance shape of the transformer structure which the electromagnetic device concerning the embodiment of the present invention comprises. It is a perspective view which shows the external appearance shape of the transformer molded object which concerns on embodiment of this invention. It is a sectional side view which shows the cross-section of the transformer molded object which concerns on embodiment of this invention. It is a sectional side view which shows the cross-section of the electromagnetic device which concerns on embodiment of this invention. It is a sectional side view which shows the cross-section of the 1st resin molding metal mold | die which concerns on embodiment of this invention. It is explanatory drawing explaining the 1st procedure of the manufacturing method of the electromagnetic device which concerns on embodiment of this invention. It is explanatory drawing explaining the 2nd procedure of the manufacturing method of the electromagnetic device which concerns on embodiment of this invention. It is explanatory drawing explaining the 3rd procedure of the manufacturing method of the electromagnetic device which concerns on embodiment of this invention. It is explanatory drawing explaining the 4th procedure of the manufacturing method of the electromagnetic device which concerns on embodiment of this invention. It is a sectional side view which shows the cross-section of the 2nd mold for resin molding which concerns on embodiment of this invention. It is explanatory drawing which shows the relationship between resin pressure and elapsed time. It is a sectional side view which shows the cross-section of a product in the case of forming an insert molded body using a casting mold according to a conventional example.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Electromagnetic device 2 Core 3 Secondary coil winding 4 Primary coil winding 5 Transformer structure 9 Groove part 10 Transformer molded body 11 Resin material 12 Low voltage part 13 High voltage part 14 Meeting part 20 Mold for resin molding 23 Cavity 30 Low voltage part side gate 31 High voltage part side gate 32 Holding part 33 Holding part 34 Resin material injection port 40 Mold for resin molding 43 Low voltage part side resin material injection port 44 High voltage part side resin material injection port 50 Resin pressure sensor A Clearance G Molten resin P Parting line

Claims (11)

A cavity into which a molten resin is injected by inserting a transformer molded body in which an outer periphery of a transformer structure having a core and a coil winding wound on a side surface of the core is sealed with an insulating material;
A holding part for holding the low voltage part side of the transformer molded body;
A low voltage part side gate provided on the low voltage part side of the transformer molded body;
Using a mold for resin molding comprising a high voltage part side gate provided on the high voltage part side of the transformer molded body,
Holding the low voltage part side of the transformer molded body by the holding part,
Next, the molten resin is injected into the cavity from the high voltage portion side gate,
Next, the molten resin is injected into the cavity from the low voltage portion side gate at a predetermined timing when the molten resin encloses the high voltage portion of the transformer molded body, and the entire transformer molded body is sealed with a resin material. A method for manufacturing an electromagnetic device.   2. The method of manufacturing an electromagnetic device according to claim 1, wherein pressures of the molten resin injected into the cavity from the high-voltage part side gate are substantially equal in a direction facing each other through the transformer molded body.   The method for manufacturing an electromagnetic device according to claim 1, wherein the transformer molded body inserted into the cavity is preheated at a temperature equal to or lower than a melting point of the resin material.   4. The method of manufacturing an electromagnetic device according to claim 1, wherein the transformer molded body is positioned in the holding portion by pressure of the molten resin injected from the high voltage portion side gate. 5.   By making the flow length from the resin material supply part supplying the molten resin to the low voltage part side gate longer than the flow length from the resin material supply part to the high voltage part side gate, the low voltage part 5. The electromagnetic wave according to claim 1, wherein the injection timing of the molten resin from the side gate is delayed with respect to the injection timing of the molten resin from the high voltage portion side gate. 6. Device manufacturing method.   5. The molten resin injected from the high-voltage part side gate and the molten resin injected from the low-voltage part side gate are controlled independently, respectively. A method for manufacturing an electromagnetic device.   7. The predetermined timing at which the molten resin encloses the high voltage portion of the transformer molded body is a point in time when the resin pressure at the predetermined portion in the cavity reaches a set value. The manufacturing method of the electromagnetic device in any one of.   The molten resin injected from the high-voltage part side gate and the molten resin injected from the low-voltage part side gate were injected from the high-voltage part side gate at the center in the thickness direction of the plane where the melted resin met in the cavity. 8. The electromagnetic device according to claim 1, wherein either one of the molten resin and the molten resin injected from the low voltage side gate is submerged in the other molten resin. 9. Manufacturing method. The outer periphery of a transformer molded body having a core and a coil winding wound on the side surface of the core is sealed with an insulating material to obtain a transformer molded body, and the outer periphery of the transformer molded body is sealed with a resin material. An electromagnetic device,
The resin material filled in the outer periphery of the transformer molded body is molded by wrapping the transformer molded body so that there is no opening or boundary portion at least in the outer periphery on the high voltage part side of the transformer molded body. ,
An electromagnetic device manufactured by the manufacturing method according to claim 1.   A discharge lamp device comprising the electromagnetic device according to claim 9. A lighting fixture comprising the discharge lamp device according to claim 10.

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