JP2007049077A

JP2007049077A - Mold coil and method for manufacturing the same

Info

Publication number: JP2007049077A
Application number: JP2005234421A
Authority: JP
Inventors: Teruhiko Maeda; 照彦前田; Hiroshi Sonobe; 浩園部; Yoshikazu Takeuchi; 美和竹内; Satoshi Kida; 聡木田; Yusuke Shima; 裕介陦
Original assignee: Toshiba Corp; Toshiba Industrial Products Manufacturing Corp
Current assignee: Toshiba Corp; Toshiba Industrial Products and Systems Corp
Priority date: 2005-08-12
Filing date: 2005-08-12
Publication date: 2007-02-22

Abstract

<P>PROBLEM TO BE SOLVED: To prevent the generation of partial discharge between coil conductors without suppressing the voltage between the coil conductors, and also without enlarging the insulation distances between the coil conductors. <P>SOLUTION: A mold coil has a coil 2, a liquid-phase insulator 3 when used covering the coil 2, and a mold resin 4 formed by covering the insulator. The liquid-phase insulator 3 when used well wraps up a coil conductor 2a without generating void by spreading over every corner of the coil conductor 2a because it is in liquid-phase. The generation of partial discharge between the coil conductors 2a is prevented without suppressing the voltage between the coil conductors 2a, and also without enlarging the insulation distances between the coil conductors 2a because the coil conductors are sufficiently insulated. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

本発明は、コイルの絶縁構造を改良したモールドコイル及びそれの製造方法に関する。 The present invention relates to a molded coil having an improved coil insulation structure and a method for manufacturing the same.

従来より、配電用の変圧器等に用いられるモールドコイルにおいては、コイル導体を巻回して構成したコイルを、その周囲に成形するモールド樹脂で直接覆っていた（例えば特許文献１参照）。
特開２００３−２５７７５０号公報 Conventionally, in a molded coil used for a power distribution transformer or the like, a coil formed by winding a coil conductor is directly covered with a molding resin molded around the coil coil (see, for example, Patent Document 1).
JP 2003-257750 A

しかしながら、モールド樹脂には成形硬化時にボイドができやすく、特に、モールド樹脂がコイル導体と接する部分、更にその中でも、近接したコイル導体同士で形成される多くの隅の部分に空気が封じ込められてボイドができやすい。そして、そのようにできたボイドは、コイル導体間の部分放電を発生する因となるものであり、この部分放電の発生を避けるため、コイル導体間の電圧を抑制したり、コイル導体間の絶縁距離を大きくとったりすることが行われてきたが、そのうちのコイル導体間の電圧を抑制する策では、高電圧クラスの変圧器等の機器への適用が困難であり、コイル導体間の絶縁距離を大きくとる策では、モールドコイルの大形化、ひいては変圧器など適用機器の大形化を招来していた。 However, voids are easily formed in the mold resin when it is molded and hardened. In particular, air is trapped in the portions where the mold resin is in contact with the coil conductors, and in particular, the corners formed by the adjacent coil conductors. Easy to do. The voids thus formed cause partial discharge between the coil conductors. In order to avoid this partial discharge, the voltage between the coil conductors is suppressed or the insulation between the coil conductors is insulated. Although it has been practiced to increase the distance, the measures to suppress the voltage between the coil conductors are difficult to apply to devices such as high voltage class transformers, and the insulation distance between the coil conductors is reduced. The measure to take a large scale has led to an increase in the size of the molded coil and, in turn, an increase in the size of the applied equipment such as a transformer.

本発明は上述の事情に鑑みてなされたものであり、従ってその目的は、コイル導体間の電圧を抑制したり、コイル導体間の絶縁距離を大きくとったりすることなく、コイル導体間の部分放電の発生を避けることのできるモールドコイル及びそれの製造方法を提供するにある。 The present invention has been made in view of the above circumstances. Therefore, the object of the present invention is to suppress the partial discharge between the coil conductors without suppressing the voltage between the coil conductors or increasing the insulation distance between the coil conductors. An object of the present invention is to provide a molded coil and a method of manufacturing the same that can avoid the occurrence.

上記目的を達成するために、本発明のモールドコイルは、第１に、コイルと、このコイルを覆った、使用時の状態が液相の絶縁物と、この絶縁物を覆って成形されたモールド樹脂とを具備して成ることを特徴とする（請求項１の発明）。 In order to achieve the above object, a molded coil according to the present invention includes, firstly, a coil, an insulator in a liquid phase when in use, and a mold formed by covering the insulator. It is characterized by comprising resin (Invention of Claim 1).

本発明のモールドコイルの製造方法は、上記第１のモールドコイルを製造するのに、コイルを熱溶融性の第１の樹脂で覆い、その後に、第１の樹脂の溶融温度より硬化温度の低い熱硬化性のモールド樹脂で第１の樹脂を覆い、この状態で、それらを第１の樹脂の溶融温度より高い温度で加熱し、それによって溶融した第１の樹脂を流し出した後に、第１の樹脂が存在した跡の空間に液相の絶縁物を流し込んで充填することを特徴とする（請求項３の発明）。 In the method for producing a molded coil according to the present invention, in order to produce the first molded coil, the coil is covered with a heat-meltable first resin, and then the curing temperature is lower than the melting temperature of the first resin. The first resin is covered with a thermosetting mold resin, and in this state, the first resin is heated at a temperature higher than the melting temperature of the first resin, and thereby the molten first resin is poured out, A liquid phase insulator is poured into the space where the resin is present and filled (invention of claim 3).

本発明のモールドコイルは、第２に、コイルと、このコイルを覆った含浸性材料から成る第１の絶縁物と、この第１の絶縁物を覆った非含浸性材料から成る第２の絶縁物と、この第２の絶縁物を覆って成形されたモールド樹脂と、前記第１の絶縁物に含浸された液相の第３の絶縁物とを具備して成ることを特徴とする（請求項４の発明）。 Secondly, the molded coil of the present invention includes a coil, a first insulator made of an impregnating material covering the coil, and a second insulation made of a non-impregnating material covering the first insulator. And a mold resin formed so as to cover the second insulator, and a liquid-phase third insulator impregnated in the first insulator. Item 4).

本発明のモールドコイルの製造方法は、上記第２のモールドコイルを製造するのに、コイルを第１の絶縁物で覆い、その後に、第１の絶縁物を第２の絶縁物で覆い、この状態で、更に第２の絶縁物をモールド樹脂で覆い、そのモールド樹脂で前記第２の絶縁物を覆う前、又は覆った後に、前記第１の絶縁物に液相の第３の絶縁物を含浸させることを特徴とする（請求項５の発明）。 According to the method of manufacturing a molded coil of the present invention, in order to manufacture the second molded coil, the coil is covered with a first insulator, and thereafter, the first insulator is covered with a second insulator. In this state, the second insulator is further covered with a mold resin, and before or after the second insulator is covered with the mold resin, a liquid phase third insulator is applied to the first insulator. It is impregnated (Invention of Claim 5).

上記第１の手段を採用したモールドコイルによれば、コイルを覆った、使用時の状態が液相の絶縁物が、液相ゆえに、コイル導体の隅々までよく行き渡ってボイドを生じることなくコイル導体を包み込む。かくして、コイル導体の絶縁が充分にできることから、コイル導体間の部分放電の発生も、コイル導体間の電圧を抑制したり、コイル導体間の絶縁距離を大きくとったりすることなく、避けることができる。
又、上記第１の手段を採用したモールドコイルを製造する方法によれば、上述の効果を奏するモールドコイルを合理的に製造できる。 According to the molded coil adopting the first means, the coil is covered, and the in-use liquid phase insulator is in the liquid phase. Enclose the conductor. Thus, since the coil conductors can be sufficiently insulated, the occurrence of partial discharge between the coil conductors can be avoided without suppressing the voltage between the coil conductors or increasing the insulation distance between the coil conductors.
In addition, according to the method of manufacturing a molded coil employing the first means, a molded coil having the above-described effects can be reasonably manufactured.

一方、第２の手段を採用したモールドコイルによれば、コイルを覆った含浸性材料から成る第１の絶縁物に含浸された液相の第３の絶縁物が、やはり液相ゆえに、コイル導体の隅々までよく行き渡ってボイドを生じることなくコイル導体を包み込む。かくして、コイル導体の絶縁が充分にできることから、コイル導体間の部分放電の発生も、コイル導体間の電圧を抑制したり、コイル導体間の絶縁距離を大きくとったりすることなく、避けることができる。
又、上記第２の手段を採用したモールドコイルを製造する方法によれば、上述の効果を奏するモールドコイルを合理的に製造できる。 On the other hand, according to the molded coil adopting the second means, the third conductor in the liquid phase impregnated in the first insulator made of the impregnating material covering the coil is also the coil conductor because the liquid phase is the third insulator. Wrap around the coil conductors and wrap the coil conductor without creating voids. Thus, since the coil conductors can be sufficiently insulated, the occurrence of partial discharge between the coil conductors can be avoided without suppressing the voltage between the coil conductors or increasing the insulation distance between the coil conductors.
In addition, according to the method of manufacturing a molded coil employing the second means, a molded coil that exhibits the above-described effects can be reasonably manufactured.

以下、本発明の第１実施例（第１の実施形態）につき、図１を参照して説明する。
図１には、完成状態のモールドコイル１を示している。このモールドコイル１は、コイル２と、このコイル２を覆った絶縁物３と、この絶縁物３を覆って成形されたモールド樹脂４とから成っている。
しかして、そのうちのコイル２は、線状のコイル導体２ａを円筒状にて多重に巻回して成るものであり、図中上下間の一部は二点鎖線で略図示して表している。 Hereinafter, a first example (first embodiment) of the present invention will be described with reference to FIG.
FIG. 1 shows the molded coil 1 in a completed state. The mold coil 1 includes a coil 2, an insulator 3 that covers the coil 2, and a mold resin 4 that is molded to cover the insulator 3.
The coil 2 is formed by winding a linear coil conductor 2a in a cylindrical shape in a multiple manner, and a part between the upper and lower sides in the drawing is schematically shown by a two-dot chain line.

これに対して、絶縁物３は、使用時の状態が液相のものであり、例えば樹脂で、コイル２を包み込んでその周囲に成形され、この成形されて硬化したときには固相であるが、後に加熱されることによって液相となるものである。
そして、モールド樹脂４は、上述のコイル２を覆って成形された絶縁物３を包み込んでその周囲に成形したものであり、上記絶縁物３には、溶融温度（融点）がこのモールド樹脂４の溶融温度より低いものを使用している。 On the other hand, the insulator 3 is in a liquid phase at the time of use. For example, the resin 3 wraps the coil 2 around the coil 2 and is molded around it. It becomes a liquid phase by being heated later.
The mold resin 4 wraps around the insulator 3 formed so as to cover the coil 2 and is molded around the insulator 3. The insulator 3 has a melting temperature (melting point) of the mold resin 4. The one below the melting temperature is used.

そこで、このものの場合、モールドコイル１の完成後、例えばコイル２に通電することによって、このコイル２をモールド樹脂４の溶融温度以下であって絶縁物３の溶融温度以上の温度に加熱すると、モールド樹脂４を溶融させずに絶縁物３を溶融させ得るものであり、かくして絶縁物３を液相にしている。又、この場合、コイル２に通電して絶縁物３を溶融させる温度は、モールドコイル１の使用時（変圧器等に適用して運転するとき）の温度ともしており、かくして、絶縁物３を使用時の状態が液相となるようにしている。 Therefore, in this case, after the mold coil 1 is completed, for example, by energizing the coil 2, the coil 2 is heated to a temperature lower than the melting temperature of the mold resin 4 and higher than the melting temperature of the insulator 3. The insulator 3 can be melted without melting the resin 4, and thus the insulator 3 is in a liquid phase. In this case, the temperature at which the coil 2 is energized to melt the insulator 3 is also the temperature when the molded coil 1 is used (when it is operated by being applied to a transformer or the like). Is in a liquid phase.

以上のように構成したモールドコイル１によれば、コイル２を覆った、使用時の状態が液相の絶縁物３が、液相ゆえに、コイル導体２ａの隅々までよく行き渡ってボイドを生じることなくコイル導体２ａを包み込む。かくして、コイル導体２ａの絶縁が充分にできることから、コイル導体２ａ間の部分放電の発生も、コイル導体２ａ間の電圧を抑制したり、コイル導体２ａ間の絶縁距離を大きくとったりすることなく、避けることができる。そして、そのうちの、コイル導体２ａ間の電圧を抑制できることで、高電圧クラスの変圧器等の機器への適用が容易に可能となり、コイル導体２ａ間の絶縁距離を大きくとる必要がなくなることで、モールドコイルの大形化、ひいては変圧器など適用機器の大形化を避けることができる。 According to the molded coil 1 configured as described above, the insulator 3 that is in a liquid phase when in use and covers the coil 2 is well spread to every corner of the coil conductor 2a because of the liquid phase, and voids are generated. Without wrapping the coil conductor 2a. Thus, since the coil conductor 2a can be sufficiently insulated, the occurrence of partial discharge between the coil conductors 2a is avoided without suppressing the voltage between the coil conductors 2a or increasing the insulation distance between the coil conductors 2a. be able to. And, by being able to suppress the voltage between the coil conductors 2a, it becomes possible to easily apply to devices such as high voltage class transformers, and it becomes unnecessary to take a large insulation distance between the coil conductors 2a. It is possible to avoid an increase in the size of the mold coil and, in turn, an increase in the size of the application device such as a transformer.

以上に対して、図２ないし図５は本発明の第２ないし第５実施例（第２ないし第５の実施形態）を示すもので、第１実施例と同一の部分には同一の符号を付して説明を省略し、異なる部分についてのみ述べる。 2 to 5 show the second to fifth examples (second to fifth embodiments) of the present invention. The same reference numerals are used for the same parts as in the first example. A description will be omitted, and only different parts will be described.

［第２実施例］
図２に示す第２実施例においては、モールドコイル１の製造方法として、まず、（ａ）図に示すようにコイル２を形成する。次いで、（ｂ）図に示すように、コイル２の周囲に第１の樹脂１１を成形して、この第１の樹脂１１によりコイル２を覆う。このとき、第１の樹脂１１には、成形型注入に供した部分を凸部１１ａとして上方に残す。 [Second Embodiment]
In the second embodiment shown in FIG. 2, as a method of manufacturing the molded coil 1, first, the coil 2 is formed as shown in FIG. Next, as shown in FIG. 5B, the first resin 11 is molded around the coil 2, and the coil 2 is covered with the first resin 11. At this time, in the first resin 11, a portion subjected to mold injection is left as a convex portion 11a.

その後、（ｃ）図に示すように、第１の樹脂１１の周囲にモールド樹脂４を成形して、このモールド樹脂４により第１の樹脂１１を覆う。このとき、第１の樹脂１１の上記凸部１１ａは、上面部をモールド樹脂４の成形上面部に露出させる。モールド樹脂４は、第１の樹脂１１の溶融温度より硬化温度の低い熱硬化性のものであり、換言すれば、第１の樹脂１１がモールド樹脂４の硬化温度より溶融温度の高い熱溶融性のものである。具体的には、例えば第１の樹脂１１として、溶融温度が１２０〔℃〕のケトン樹脂を使用し、モールド樹脂４として、一次硬化温度が１００〔℃〕のエポキシ樹脂を使用している。なお、エポキシ樹脂は二次硬化温度が１３０〔℃〕である。 Thereafter, as shown in FIG. 3C, a mold resin 4 is molded around the first resin 11 and the first resin 11 is covered with the mold resin 4. At this time, the convex portion 11 a of the first resin 11 exposes the upper surface portion to the molding upper surface portion of the mold resin 4. The mold resin 4 is a thermosetting resin having a lower curing temperature than the melting temperature of the first resin 11. In other words, the first resin 11 has a higher melting temperature than the curing temperature of the mold resin 4. belongs to. Specifically, for example, a ketone resin having a melting temperature of 120 [° C.] is used as the first resin 11, and an epoxy resin having a primary curing temperature of 100 [° C.] is used as the mold resin 4. The epoxy resin has a secondary curing temperature of 130 [° C.].

次に、（ｄ）図に示すように、成形品の上下を反転させて、その成形品を第１の樹脂１１の溶融温度より高い温度で加熱する。すると、第１の樹脂１１が溶融する前の温度段階でモールド樹脂４が硬化し、この状態で、第１の樹脂１１が溶融する温度に達して以降、第１の樹脂１１が凸部１１ａも含めて溶融する。そして、第１の樹脂１１が溶融したなら、その後に、溶融した第１の樹脂１１を凸部１１ａから順に流し出す。 Next, as shown in FIG. 4D, the molded product is turned upside down and the molded product is heated at a temperature higher than the melting temperature of the first resin 11. Then, the mold resin 4 is cured at a temperature stage before the first resin 11 is melted, and after reaching the temperature at which the first resin 11 is melted in this state, the first resin 11 is also protruded 11a. It melts including. When the first resin 11 is melted, the melted first resin 11 is subsequently poured out from the convex portion 11a.

この後、（ｅ）図に示すように、成形品の上下を元に戻して、第１の樹脂１１が存在した跡の空間に液相の絶縁物１２を流し込んで充填する。液相の絶縁物１２は、この場合、例えば植物由来のエステル油など、生分解性のものであり、モールドコイル１の使用前から使用時、使用後に至るまで液相である。なお、前記第１の樹脂１１の凸部１１ａが存在した跡の空間には、栓１３を装填することにより、液相の絶縁物１２の流出を防止する。 Thereafter, as shown in FIG. 4E, the upper and lower sides of the molded product are returned to the original state, and the liquid phase insulator 12 is poured into the space where the first resin 11 was present to fill it. In this case, the liquid phase insulator 12 is biodegradable, such as plant-derived ester oil, and is in a liquid phase from before the use of the mold coil 1 to when it is used and after use. In addition, a plug 13 is installed in the space where the convex portion 11a of the first resin 11 is present, thereby preventing the liquid phase insulator 12 from flowing out.

このようにしても、コイル２を覆った、使用時の状態が液相の絶縁物１２が、液相ゆえに、コイル導体２ａの隅々までよく行き渡ってボイドを生じることなくコイル導体２ａを包み込むから、コイル導体２ａの絶縁が充分にできて、コイル導体２ａ間の部分放電の発生を、コイル導体２ａ間の電圧を抑制したり、コイル導体２ａ間の絶縁距離を大きくとったりすることなく、避けることができる。 Even if it does in this way, since the insulator 12 of a liquid phase which covers the coil 2 is in a liquid state, it spreads to every corner of the coil conductor 2a well and wraps around the coil conductor 2a without generating a void. The coil conductor 2a can be sufficiently insulated, and the occurrence of partial discharge between the coil conductors 2a should be avoided without suppressing the voltage between the coil conductors 2a or increasing the insulation distance between the coil conductors 2a. Can do.

又、液相の絶縁物１２には、上述の植物由来のエステル油など、生分解性のものを使用しており、それによって、モールドコイル１を棄却したときの絶縁物１２の分解が微生物によってでき、地球環境を悪化させることのないようにできる。
更に、上述の製造方法によれば、上述の効果を奏するモールドコイル１を合理的に製造することができる。 In addition, the liquid phase insulator 12 is made of biodegradable material such as the above-mentioned plant-derived ester oil, so that the decomposition of the insulator 12 when the molded coil 1 is discarded is caused by microorganisms. It can be done without deteriorating the global environment.
Furthermore, according to the above-described manufacturing method, the molded coil 1 having the above-described effects can be reasonably manufactured.

加えて、上記製造方法において、溶融させて流し出した第１の樹脂１１は、同製品のモールドコイル１を製造するのに繰り返し利用することが可能である。
なお、液相の絶縁物１２は、生分解性のものに限られず、鋼油やシリコンオイル等であっても良い。 In addition, in the manufacturing method, the first resin 11 melted and poured out can be repeatedly used to manufacture the molded coil 1 of the same product.
The liquid phase insulator 12 is not limited to a biodegradable material, and may be steel oil, silicon oil, or the like.

［第３実施例］
図３に示す第３実施例においては、モールドコイル１の異なる製造方法として、（ａ）図に示すようにコイル２を形成した後、（ｂ）図に示すように、コイル２を含浸性材料から成る第１の絶縁物２１で覆う。この含浸性材料から成る第１の絶縁物２１は、低密度の、独立気泡を有さない多孔質の材料から成るものであり、例えば不織布を使用する。
次いで、（ｃ）図に示すように、第１の絶縁物２１を非含浸性材料から成る第２の絶縁物２２で覆う。この非含浸性材料から成る第２の絶縁物２２には、例えばＰＥＴフィルムを使用する。又、この第２の絶縁物２２には、上部に口２２ａを形成しておく。 [Third embodiment]
In the third embodiment shown in FIG. 3, as a different manufacturing method of the molded coil 1, after forming the coil 2 as shown in FIG. 3 (a), the coil 2 is impregnated as shown in FIG. 3 (b). It covers with the 1st insulator 21 which consists of. The first insulator 21 made of the impregnating material is made of a porous material having low density and no closed cells, and for example, a nonwoven fabric is used.
Next, as shown in FIG. 3C, the first insulator 21 is covered with a second insulator 22 made of a non-impregnated material. For the second insulator 22 made of this non-impregnating material, for example, a PET film is used. The second insulator 22 has a mouth 22a formed in the upper part.

この後、（ｄ）図に示すように、第２の絶縁物２２の口２２ａから第１の絶縁物２１に液相の第３の絶縁物２３を注入して含浸させる。この液相の第３の絶縁物２３も、例えば生分解性を有する植物由来のエステル油や、鋼油、シリコンオイル等であり、モールドコイル１の使用前から使用時、使用後に至るまで液相である。
そして、その後、（ｅ）図に示すように、第２の絶縁物２２の口２２ａに栓２４を装填し、この状態で、第２の絶縁物２２の周囲にモールド樹脂４を成形して、このモールド樹脂４により第２の絶縁物２２を覆う。 Thereafter, as shown in FIG. 4D, the liquid-phase third insulator 23 is injected and impregnated into the first insulator 21 from the opening 22a of the second insulator 22. The liquid phase third insulator 23 is also, for example, biodegradable plant-derived ester oil, steel oil, silicon oil, or the like, and the liquid phase extends from before use to after use of the mold coil 1. It is.
And after that, as shown in (e) figure, plug 24 is loaded into port 22a of second insulator 22, and in this state, molding resin 4 is molded around second insulator 22, The second insulator 22 is covered with the mold resin 4.

この結果、モールドコイル１は、この場合、コイル２と、このコイル２を覆った含浸性材料から成る第１の絶縁物２１と、この第１の絶縁物２１を覆った非含浸性材料から成る第２の絶縁物２２と、この第２の絶縁物２２を覆って成形されたモールド樹脂４と、前記第１の絶縁物２１に含浸された液相の第３の絶縁物２３とを具備して成るもので、そのうちの、コイル２を覆った、使用時の状態が液相の第３の絶縁物２３が、液相ゆえに、コイル導体２ａの隅々までよく行き渡ってボイドを生じることなくコイル導体２ａを包み込むから、コイル導体２ａの絶縁が充分にできて、コイル導体２ａ間の部分放電の発生を、コイル導体２ａ間の電圧を抑制したり、コイル導体２ａ間の絶縁距離を大きくとったりすることなく、避けることができる。 As a result, the molded coil 1 in this case is composed of the coil 2, the first insulator 21 made of the impregnating material covering the coil 2, and the non-impregnating material covering the first insulator 21. A second insulator 22; a mold resin 4 molded over the second insulator 22; and a liquid phase third insulator 23 impregnated in the first insulator 21. Among them, the third insulator 23 that covers the coil 2 and is in a liquid phase at the time of use spreads to every corner of the coil conductor 2a because of the liquid phase, so that no void is generated. Since the conductor 2a is wrapped, the coil conductor 2a can be sufficiently insulated, and partial discharge between the coil conductors 2a can be suppressed, the voltage between the coil conductors 2a can be suppressed, and the insulation distance between the coil conductors 2a can be increased. Can be avoided without

又、この場合、コイル２を覆った含浸性材料から成る第１の絶縁物２１を非含浸性材料から成る第２の絶縁物２２で覆うことで、含浸性材料から成る第１の絶縁物２１に含浸させる液相の第３の絶縁物２３を漏らすことのないようにできる。 In this case, the first insulator 21 made of the impregnating material is covered with the second insulator 22 made of the non-impregnating material so that the first insulator 21 made of the impregnating material is covered. The third insulator 23 in the liquid phase to be impregnated into can be prevented from leaking.

但し、液相の第３の絶縁物２３は、モールド樹脂４で第２の絶縁物２２を覆う前に限られず、覆った後に第１の絶縁物２１に含浸させるようにしても良いもので、この場合には、モールド樹脂４が第１の絶縁物２１に含浸してコイル２の周囲にボイドの発生を伴って成形されるのを、第２の絶縁物２２で防ぐことができる。
そして、上述の製造方法によれば、上述の効果を奏するモールドコイル１を合理的に製造することができる。 However, the third insulator 23 in the liquid phase is not limited to the case where the second insulator 22 is covered with the mold resin 4, and the first insulator 21 may be impregnated after the covering. In this case, the second insulator 22 can prevent the molding resin 4 from being impregnated in the first insulator 21 and molded around the coil 2 with the generation of voids.
And according to the above-mentioned manufacturing method, the mold coil 1 which has the above-mentioned effect can be manufactured reasonably.

［第４実施例］
図４に示す第４実施例においては、モールド樹脂４にクラック容易な弱点部３１を複数箇所形成しており、その形成は、この場合、第１実施例の絶縁物３の外周部に、これが硬化する段階で、先鋭な突起部３２を複数形成することにより、そのそれぞれに対応したモールド樹脂４の箇所を局部的に薄肉にすることで行っているが、それに代えて、第２実施例の第１の樹脂１１の外周部、又は第３実施例の第２の絶縁物２２の外周部に、同様に、先鋭な突起部を複数形成することにより行っても良い。 [Fourth embodiment]
In the fourth embodiment shown in FIG. 4, a plurality of weak points 31 that are easily cracked are formed in the mold resin 4, and in this case, this is formed on the outer peripheral portion of the insulator 3 of the first embodiment. At the stage of curing, by forming a plurality of sharp protrusions 32, the portion of the mold resin 4 corresponding to each of them is locally thinned, but instead of the second embodiment Similarly, a plurality of sharp protrusions may be formed on the outer peripheral portion of the first resin 11 or the outer peripheral portion of the second insulator 22 of the third embodiment.

このようにすることにより、モールドコイル１を棄却するときのモールド樹脂４の破壊が、弱点部３１からモールド樹脂４にクラックを生じさせて容易にでき、それによって、コイル２の回収も容易にできる。 By doing in this way, destruction of the mold resin 4 at the time of rejecting the mold coil 1 can be easily caused by causing a crack in the mold resin 4 from the weak point portion 31, thereby easily collecting the coil 2. .

なお、モールド樹脂４を破壊するについては、第１実施例の絶縁物３、第２実施例の絶縁物１２、及び第３実施例の第３の絶縁物２３を温度上昇させて、それらの体積を膨張させることにより、モールド樹脂４に内側から破壊力を与える方法で行うようにすると、一層容易にできる。 For destroying the mold resin 4, the temperature of the insulator 3 of the first embodiment, the insulator 12 of the second embodiment, and the third insulator 23 of the third embodiment is increased, and the volume thereof is increased. If the mold resin 4 is expanded by a method in which a destructive force is applied to the mold resin 4 from the inside, this can be further facilitated.

又、それとは異なる方法として、第１実施例の絶縁物３を液相にして、又は最初から液槽の第２実施例の絶縁物１２、及び第３実施例の第３の絶縁物２３を流し出して、その跡の空間に水を流し入れ、この水を凍らせることで体積膨張させ、それによって、モールド樹脂４に内側から破壊力を与える方法を採るようにしても良い。
更に、これらの場合、モールド樹脂４に弱点部３１を形成していると、モールド樹脂４の破壊が一層容易にできるが、弱点部３１はモールド樹脂４に形成していなくても、モールド樹脂４の破壊はそれなりに容易にできる。 Also, as a different method, the insulator 3 of the first embodiment is made into a liquid phase, or the insulator 12 of the second embodiment of the liquid tank and the third insulator 23 of the third embodiment from the beginning. A method may be adopted in which water is poured into the space of the trace and the volume is expanded by freezing the water, thereby giving the mold resin 4 a destructive force from the inside.
Further, in these cases, if the weak point portion 31 is formed in the mold resin 4, the mold resin 4 can be more easily destroyed. However, even if the weak point portion 31 is not formed in the mold resin 4, the mold resin 4 Can be easily destroyed.

［第５実施例］
図５に示す第５実施例においては、モールド樹脂４とコイル２との間に、絶縁空間４１を形成するに留めている。コイル導体２ａ間の電圧のレベルが低い場合には、このようにしても、コイル導体２ａ間の絶縁性を確保することができる。又、その絶縁空間４１には、モールドコイル１を棄却するときに、上述のように液体を流し込んでそれを温度上昇させたり、凍結させたりして体積膨張させることにより、モールド樹脂４に内側から破壊力を与えるようにすると良い。更に、この場合も、モールド樹脂４に弱点部３１を形成していると、モールド樹脂４の破壊が一層容易にできるが、弱点部３１はモールド樹脂４に形成していなくても、モールド樹脂４の破壊はそれなりに容易にできる。 [Fifth embodiment]
In the fifth embodiment shown in FIG. 5, the insulating space 41 is only formed between the mold resin 4 and the coil 2. When the voltage level between the coil conductors 2a is low, the insulation between the coil conductors 2a can be secured even in this way. Further, when the mold coil 1 is rejected, the liquid is poured into the insulating space 41 and the volume is expanded by increasing the temperature or freezing as described above. It is good to give destructive power. Further, in this case, if the weak point portion 31 is formed in the mold resin 4, the mold resin 4 can be more easily broken. However, even if the weak point portion 31 is not formed in the mold resin 4, the mold resin 4 Can be easily destroyed.

このほか、本発明は上記し且つ図面に示した実施例にのみ限定されるものではなく、要旨を逸脱しない範囲内で適宜変更して実施し得る。 In addition, the present invention is not limited to the embodiments described above and shown in the drawings, and can be implemented with appropriate modifications within a range not departing from the gist.

本発明の第１実施例を示す斜視断面図1 is a perspective sectional view showing a first embodiment of the present invention. 本発明の第２実施例を（ａ）〜（ｅ）で製造工程順に示す斜視断面図The perspective sectional view showing the 2nd example of the present invention in order of a manufacturing process in (a)-(e). 本発明の第３実施例を示す図２相当図FIG. 2 equivalent view showing a third embodiment of the present invention. 本発明の第４実施例を示す図１相当図FIG. 1 equivalent view showing a fourth embodiment of the present invention. 本発明の第５実施例を示す図１相当図FIG. 1 equivalent view showing a fifth embodiment of the present invention.

Explanation of symbols

図面中、１はモールドコイル、２はコイル、３は使用時の状態が液相の絶縁物、４はモールド樹脂、１１は第１の樹脂、１２は液相の絶縁物、２１は第１の絶縁物、２２は第２の絶縁物、２３は液相の第３の絶縁物、３１は弱点部、４１は絶縁空間を示す。 In the drawings, 1 is a mold coil, 2 is a coil, 3 is a liquid phase insulator in use, 4 is a mold resin, 11 is a first resin, 12 is a liquid phase insulator, and 21 is a first phase. Insulators, 22 is a second insulator, 23 is a liquid phase third insulator, 31 is a weak spot, and 41 is an insulating space.

Claims

Coils,
Covering this coil, the state of use is a liquid phase insulator,
A molded coil comprising a molded resin formed to cover the insulator.

2. The molded coil according to claim 1, wherein the insulator is biodegradable.

The coil is covered with a heat-meltable first resin, and then the first resin is covered with a thermosetting mold resin having a curing temperature lower than the melting temperature of the first resin. In this state, the first resin is covered with the first resin. Heating at a temperature higher than the melting temperature of the resin, and after pouring out the melted first resin, a liquid phase insulator is poured into the space where the first resin was present and filled. The method for producing a molded coil according to claim 1.

Coils,
A first insulator made of an impregnating material covering the coil;
A second insulator made of a non-impregnated material covering the first insulator;
A mold resin molded to cover the second insulator;
A molded coil comprising: a liquid phase third insulator impregnated in the first insulator.

The coil is covered with a first insulator, and then the first insulator is covered with a second insulator. In this state, the second insulator is further covered with a mold resin, and the second resin is covered with the mold resin. 5. The method of manufacturing a molded coil according to claim 4, wherein the first insulator is impregnated with a liquid phase third insulator before or after the insulator is covered. 6.

The mold coil according to claim 1 or 4, wherein the mold resin has a weak point portion that is easily cracked.

Coils,
A mold resin molded over the coil,
A mold coil, wherein an insulating space is formed between the mold resin and the coil.