JP2008312386A - Coil and method of manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To fill a gap between conductors forming a coil of a motor core with a highly thermally-conductive material containing much inorganic filler and to effectively transmit heat caused in the coil to teeth. <P>SOLUTION: A method includes: a step of making the conductor pass through an adhesion material and forming an adhesion material layer on a surface of the conductor; a step of making the conductor with the adhesion material layer formed on a surface thereof pass through the inorganic particles and bonding the inorganic particles to the adhesion material layer; a step of curing the adhesion material layer to which the inorganic particles are bonded and obtaining a conductor coated with inorganic particles, where the inorganic particles are fixed to the surface of the conductor; and a step of winding the conductor coated with the inorganic particles to the teeth of the motor core. The steps are sequentially and continuously performed to form the coil. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a coil and a method for manufacturing the coil, and more particularly to a coil that can effectively transmit generated heat to a tooth to improve heat dissipation, and a method for manufacturing the coil that realizes the coil. .

In general, as a method for improving the output of the motor, means for increasing the magnetomotive force by reducing the loss by increasing the density of the coil winding or increasing the current flowing to the coil is taken.
However, when the magnetomotive force is increased, a lot of Joule heat is generated in the coil, the Joule heat increases the temperature of the motor, and the efficiency of the motor decreases. Therefore, in order to improve the output of the motor, it is necessary to sufficiently radiate the Joule heat generated in the coil to the outside of the motor.
Therefore, a motor stator structure that dissipates heat generated in the coil outside the motor by covering the stator coil provided on the stator core with a high thermal conductive mold resin filled with inorganic fillers that are inorganic thermal conductive material particles. Is disclosed (for example, see Patent Document 1).
Moreover, the thermal conductivity between the coil and the thermal conductivity between the coil and the stator can be reduced by dripping and impregnating the coil inserted into the slot with a highly thermally conductive varnish added with filler, which is inorganic thermal conductive material particles. An improved electric motor is disclosed (for example, see Patent Document 2).

JP 2005-198466 A (page 3) JP 2003-244907 A (page 3)

In a motor stator structure that improves heat dissipation to the outside of the motor by covering the stator coil with a high thermal conductive mold resin filled with inorganic filler, the viscosity of the high thermal conductive mold resin used is high, and the high thermal conductive mold resin Is difficult to fill in the gaps existing between the conductors in the coil. For this reason, the motor stator structure has a problem that a gap, which is one of the factors that hinder heat dissipation from the coil to the teeth side, remains between the conductors, which becomes a heat insulating layer and does not provide a sufficient heat conduction effect. It was.
Moreover, the high thermal conductive mold resin used for manufacturing the motor stator structure is a resin filled with an inorganic filler. Since the viscosity of the inorganic filler increases due to aggregation over time, the pot life is short, and this motor The stator structure has a problem of high manufacturing cost.

In an electric motor formed by dripping and impregnating a highly heat conductive varnish obtained by adding filler to a coil, the varnish is impregnated into a gap existing between conductors in the coil. However, the varnish used for this electric motor needs to have a viscosity that allows dripping impregnation, and the amount of filler added to the varnish is limited. That is, in the electric motor formed in this way, the varnish with a large amount of filler is not used, and the heat conductivity of the cured varnish of the coil portion is not large. There is a problem that the improvement in the thermal conductivity between the coil and the stator is small.
Further, the varnish used to manufacture the motor also has a problem that the pot life is short because the varnish thickens due to aggregation of the dispersed filler over time, and this motor is also expensive to manufacture.

  The present invention has been made to solve the above-described problems. The object of the present invention is to generate a high thermal conductive material containing a large amount of inorganic filler in a space between conductive wires forming a coil. It is to provide a coil and a method of manufacturing the coil that can effectively transmit heat to the teeth and improve motor efficiency.

  The method for manufacturing a coil according to the present invention includes a step of passing a conductive wire through an adhesive material to form an adhesive material layer on the surface of the conductive wire, and a conductive wire having the adhesive material layer formed on the surface thereof, passing through the inorganic particles. A step of adhering inorganic particles to the adhesive layer, a step of curing the adhesive layer to which the inorganic particles have adhered, obtaining an inorganic particle-coated conductor in which the inorganic particles are fixed on the surface of the conductor, and an inorganic particle-coated conductor. The process of winding around the teeth of the motor core is performed sequentially in sequence.

  The method for manufacturing a coil according to the present invention includes a step of passing a conductive wire through an adhesive material to form an adhesive material layer on the surface of the conductive wire, and a conductive wire having the adhesive material layer formed on the surface thereof, passing through the inorganic particles. A step of adhering inorganic particles to the adhesive layer, a step of curing the adhesive layer to which the inorganic particles have adhered, obtaining an inorganic particle-coated conductor in which the inorganic particles are fixed on the surface of the conductor, and an inorganic particle-coated conductor. The process of winding around the teeth of the motor core is performed in sequence, and the gap between the conductors is filled with a coating layer with a high content of inorganic particles without gaps, so the heat generated in the coil is effective. The effect that it can be transmitted to the teeth is obtained.

Embodiment 1 FIG.
FIG. 1 is an enlarged schematic cross-sectional view of a part of a coil according to Embodiment 1 of the present invention.
As shown in FIG. 1, the coil 10 of the present embodiment has an inorganic heat conduction in which an inorganic heat conductive material particle layer (referred to as an inorganic particle layer) 51 is held on the surface of the conductive wire 2 via an adhesive material hardened layer 31. A material particle-coated conductive wire (referred to as an inorganic particle-coated conductive wire) 21 is wound around the tooth 1 of the motor core.
That is, the inorganic particle-coated conductive wire 21 is composed of the conductive wire 2 serving as the core, the adhesive material cured layer 31, and the inorganic particle layer 51 on the surface. The inorganic particle layer 51 covers the surface of the inorganic particle-coated conductive wire 21. Covers without gaps.
In the first layer of the inorganic particle-coated conductive wire 21 constituting the coil, the inorganic particle layer 51 held on the surface is in contact with the tooth 1 of the motor core. The second layer of the inorganic particle-coated conductive wire 21 is brought into contact with the inorganic particle layer 51 held on the surface of the inorganic particle-coated conductive wire 21 of the first layer so that the inorganic particle layer 51 is held on the surface. The lead wire 21 is wound around the first layer. In FIG. 1, the wound inorganic particle-coated conductive wire 21 is shown only up to the second layer. However, the third layer or more of the inorganic particle-coated conductive wire 21 is overlapped on the layer below it in the same manner as the second layer. It is wound around. The inorganic particle-coated conductive wire 21, the tooth 1 of the motor core, and the inorganic particle-coated conductive wire 21 are in close contact with each other.
That is, in the coil 10 of the present embodiment, the inorganic particle-coated conductive wire 21 is used, and the gap between the conductive wires 2 is covered with a coating layer having a high content of the inorganic particles 5 composed of the adhesive material cured layer 31 and the inorganic particle layer 51. Can be transferred to the teeth 1 effectively.

Next, the manufacturing method of the coil of this Embodiment is demonstrated using figures.
FIG. 2 is a schematic diagram of a coil manufacturing method according to Embodiment 1 of the present invention.
As shown in FIG. 2, in the coil manufacturing method of the present embodiment, the conductor 2 is continuously passed through the adhesive 3 stored in the adhesive tank 4, and the adhesive 3 is attached to the surface of the conductor 2. To form an adhesive layer.
Next, the conducting wire 2 having the adhesive material layer formed on the surface is passed through the inorganic particles 5 accommodated in the inorganic particle tank 6, and the inorganic particles 5 are adhered to the adhesive material layer on the conducting wire 2 surface.
Next, the conductive wire 2 having the inorganic particles 5 attached to the surface via the adhesive material layer is heated by the heating device 7 to cure the adhesive material layer, thereby fixing the inorganic particles 5 to the surface of the conductive wire 2 and coating the inorganic particles. Conductive wire 21 is obtained.
Finally, the inorganic particle-coated conductive wire 21 is wound around the tooth 1 of the motor core to form the coil 10.

In the present embodiment, for example, a peroxide curable silicon-based adhesive material is used as the adhesive material 3 and can be cured by heating at a temperature of 150 ° C. to 180 ° C. for about 5 minutes. By curing the adhesive material 3 in this manner, the inorganic particle 5 is transferred from the surface of the inorganic particle-coated conductor 21 due to the shearing force applied to the inorganic particle-coated conductor 21 when the inorganic particle-coated conductor 21 is wound around the tooth 1. Can be prevented from peeling off.
For the inorganic particles 5, for example, aluminum nitride, aluminum oxide, silicon nitride, titanium nitride, titanium oxide or the like is used.
Moreover, the adhesive material tank 4 is provided with a hole through which the conducting wire 2 passes through each of one side surface and a side surface facing the one side surface. The inorganic particle tank 6 is also provided with a hole through which the conducting wire 2 passes through each of one side surface and the side surface opposite to the one side surface. Further, the inorganic particle tank 6 may be provided with a dispersion mechanism such as an oscillating sieve, an ultrasonic vibration device, an air blowing device or the like that prevents aggregation and uniformly adheres the inorganic particles 5 to the surface of the conductor 2. .
As the heating device 7 for curing the adhesive material 3, for example, an electric heater, an infrared heating device, a high-frequency heating device, hot air heating for blowing hot air with a fan, or the like is used.
And the adhesive material tank 4, the inorganic particle tank 6, and the heating apparatus 7 are arrange | positioned in series, and the inorganic particle covering conducting wire 21 is formed continuously. The continuously formed inorganic particle-coated conductive wire 21 is continuously wound around the teeth 1 of the motor core.

In the coil manufacturing method of the present embodiment, an adhesive material layer is formed by attaching the adhesive material 3 to the conductive wire 2, and after the inorganic particles 5 are provided on the adhesive material layer, the adhesive material layer is cured to produce an inorganic material. The particle-coated conductive wire 21 is formed before being wound around the tooth 1. Therefore, it is possible to obtain the inorganic particle-coated conductive wire 21 having a coating layer having a high content of the inorganic particles 5 on the surface.
And in this Embodiment, since the inorganic particle covering conducting wire 21 in which the coating layer with much content of the inorganic particle 5 was provided was wound around the teeth 1 to form the coil 3, between the wound conducting wires 2 The gap can be filled with a coating layer having a high content of inorganic particles 5.

That is, in the manufacturing method of the present embodiment, the gap between the coil conductors 2 can be filled with a coating layer having a high content of the inorganic particles 5 without gaps, and the generated heat is effectively transmitted to the teeth 1. Can be obtained.
Moreover, since the coil 10 of this Embodiment is filled with the coating layer which consists of the adhesive material hardening layer 31 and the inorganic particle 5 between the conducting wires 2, this coating layer acts as an insulating layer, and in the conventional coil, Insulating means such as insulating paper and resin molded bodies (insulators), which are necessary for insulating the teeth, are unnecessary, and the cost can be reduced by reducing the number of parts.
Further, in the coil manufacturing method of the present embodiment, since the inorganic material 5 is not contained in the adhesive material 3 stored in the adhesive material tank 4, the viscosity of the adhesive material 3 due to the aggregation of the inorganic particles 5 over time is increased. In addition, since the pot life of the adhesive material 3 is long, the adhesive material 3 is not wasted and the manufacturing cost of the coil can be reduced.
The motor core of the present embodiment may be either a stator core or a rotor core.

Embodiment 2. FIG.
FIG. 2 is a schematic diagram of a coil manufacturing method according to Embodiment 2 of the present invention.
As shown in FIG. 2, the manufacturing method of the coil according to the present embodiment uses a photo-curing resin for the adhesive material 3 and an ultraviolet irradiation device 8 as a means for curing the adhesive material layer holding the inorganic particles 5. The method is the same as that of the coil manufacturing method of the first embodiment except that is used.
In the present embodiment, for example, a peroxide curable epoxy adhesive or an oxetane adhesive is used as the photocurable resin used for the adhesive 3. In addition, for example, a high-pressure mercury lamp or a metal halide lamp is used for the ultraviolet irradiation device 8.
In the case of a cation curable oxetane-based pressure-sensitive adhesive material, when a 200 W high-pressure mercury lamp is used for the ultraviolet irradiation device 8, it can be cured by ultraviolet irradiation for 10 seconds or less.

Also in the coil manufacturing method of the present embodiment, the adhesive material 3 is adhered to the conductive wire 2 before being wound around the tooth 1, and the inorganic particles 5 are provided on the adhesive material layer. There are the same operations and effects as the coil manufacturing method.
That is, also in the coil manufacturing method of the present embodiment, the adhesive material 3 is attached to the conductor 2 to form an adhesive material layer, the inorganic material 5 is provided on the adhesive material layer, the adhesive material layer is cured, and the inorganic particles Since the coated conductive wire 21 is formed before being wound around the tooth 1, the inorganic particle coated conductive wire 21 can form a coating layer having a large content of the inorganic particles 5 on the surface.
And since the inorganic particle covering conducting wire 21 provided with the coating layer with a large content rate of the inorganic particles 5 is wound around the tooth 1 to form a coil, the gap between the conducting wires wound around the coil is formed in the inorganic particle 5. Therefore, it is possible to obtain a coil that can effectively transmit the generated heat to the teeth 1.
Further, in the present embodiment, a photo-curing resin is used for the adhesive material 3, and the adhesive material 3 can be cured particularly in a short time, so that the tact time can be shortened and the productivity of the coil is further improved. By curing the adhesive 3, the inorganic particles 5 are peeled from the surface of the inorganic particle-coated conductor 21 due to the shearing force applied to the inorganic particle-coated conductor 21 when the inorganic particle-coated conductor 21 is wound around the tooth 1. Can be prevented.

  In the coil according to the present invention, the gap between the wound conductors is filled with a layer having a high content of inorganic particles, so that the generated heat can be effectively transferred to the tooth 1 and a highly efficient motor. It can be used as a coil.

FIG. 3 is a schematic cross-sectional view showing an enlarged part of the coil according to the first embodiment. 3 is a schematic diagram of a method for manufacturing a coil according to Embodiment 1. FIG. 10 is a schematic diagram of a coil manufacturing method according to Embodiment 2. FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Teeth, 2 Conductor, 3 Adhesive material, 4 Adhesive material tank, 5 Inorganic particle, 6 Inorganic particle tank, 7 Heating device, 8 Ultraviolet irradiation apparatus, 10 Coil, 21 Inorganic particle covering conducting wire,
31 A cured adhesive layer, 51 an inorganic particle layer.

Claims (4)

The conductive wire is a coil wound around a tooth of a motor core, and the conductive wire is an inorganic particle-coated conductive wire having an inorganic particle layer formed on the surface via a cured adhesive material, and the inorganic particle-coated conductive wire is the above-mentioned A coil comprising a plurality of layers wound with inorganic particle layers in contact with each other. A step of forming a pressure-sensitive adhesive layer on the surface of the conductive wire by passing the conductive wire through the pressure-sensitive adhesive material, and passing the conductive wire having the pressure-sensitive adhesive layer formed on the surface through the inorganic particles to form the pressure-sensitive adhesive layer. A step of attaching the inorganic particles, a step of curing the pressure-sensitive adhesive layer to which the inorganic particles are adhered, obtaining an inorganic particle-coated conductor in which the inorganic particles are fixed to the surface of the conductor, and the inorganic particle-coated conductor. A method of manufacturing a coil, wherein the step of winding around a tooth of a motor core is performed successively in order. The method for manufacturing a coil according to claim 2, wherein the adhesive material layer to which the inorganic particles are attached is cured by heating the adhesive material layer. The method for producing a coil according to claim 2, wherein the adhesive material layer to which the inorganic particles are attached is cured by using a photocurable resin as the adhesive material and irradiating the adhesive material layer with ultraviolet rays.

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