JP2009176984A - Coil winding system and method for fabricating molded coil - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To fabricate a wound coil composed of a bobbinless coil readily and efficiently. <P>SOLUTION: The system includes a coil winding device 15 having an upper jig 12 to which an upper plate 102 is attached and a lower jig 14 to which a lower plate 104 is attached, which are provided so as to be relatively displaceable; and a tension device 34 for applying predetermined tension to a wire rod 106 fed from a wire rod supplying source 17. The coil winding device 15 is provided with a claw section 240 having first through third split claws 241a to 241c that function as a winding section around which the wire rod 106 is wound between the upper plate 102 and lower plate 104 and that slide in a radial direction when the upper jig 12 is assembled coaxially with the lower jig 14. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a coil winding system for manufacturing a coil winding body having a coil (solenoid) incorporated in an electromagnetic device such as an electromagnetic valve and an electromagnetic actuator, and a method for manufacturing a coil molded body.

  2. Description of the Related Art Conventionally, for example, electromagnetic devices such as an electromagnetic valve that actuates a valve body by attracting a movable core to a fixed core side by exciting a coil winding body constituting a solenoid to generate an electromagnetic force are known. . In this electromagnetic device, in order to ensure electrical insulation (isolation), for example, the outer surface of the coil winding body is coated with a resin material by molding or the like.

Therefore, as disclosed in Patent Document 1, the present applicant has integrated a synthetic resin coil cover (coil covering) on the outer peripheral surface excluding the inner peripheral surface of the cylindrical bobbinless coil and both end surfaces in the axial direction. A method of manufacturing a bobbinless coil assembly that manufactures a bobbinless assembly by mechanically molding is proposed.
JP 2007-67090 A

  The present invention has been made in connection with the above proposal, and a general object of the present invention is to provide a coil winding that can easily and efficiently manufacture a coil winding body composed of a bobbinless coil. To provide a system.

  Moreover, the main object of this invention is to provide the manufacturing method of the coil molded object which can obtain the coil molded object containing the coil winding body which consists of a bobbin-less coil simply and efficiently.

  In order to achieve the above object, the present invention provides a coil winding apparatus in which an upper jig on which an upper plate is mounted and a lower jig on which a lower plate is mounted are relatively displaceable, A wire supply means for supplying a wire wound as a coil to the coil winding device; and a tensioner device for applying a predetermined tension to the wire supplied to the coil winding device. The wire device has a winding portion around which the wire is wound between the upper plate and the lower plate, and the upper jig and the lower jig are assembled coaxially. A claw portion including a plurality of divided claws that slide in the radial direction is provided.

  According to the present invention, the upper jig mounted with the upper plate and the lower jig mounted with the lower plate are assembled while being relatively displaced so that the upper plate and the lower plate are spaced apart by a predetermined distance. It is held in the state. Subsequently, the wire rod is supplied from the wire rod supply means to the coil winding device in a state where a predetermined tension is applied by the tensioner device, and the winding portion provided on the circumferential surface of the claw portion of the coil winding device is applied. The wire is wound.

  As a result, according to the present invention, the upper and lower plates arranged at a predetermined interval are held by the upper jig and the lower jig, respectively, with respect to the winding portion on the circumferential surface of the claw portion provided between the upper and lower plates. Thus, a coil winding body made of a bobbinless coil can be easily and efficiently formed by winding a wire rod.

  In this case, the coil winding body includes a coil laminated body having a coil that is sandwiched between the upper plate and the lower plate and wound with a wire and laminated in a plurality of stages, and the upper plate and the lower plate. Even if it is a bobbinless which has a tangled wire that holds the upper plate and the lower plate by alternately tangling the convex portions of the coil, and the cylindrical coil bobbin is not provided on the inner peripheral surface of the coil laminate The coil laminate is not scattered by the binding wire and is held in a stable state.

  Furthermore, by tying the tie wire so as to circulate along the side peripheral surface of the coil laminate, for example, a uniform holding force can be generated along the circumferential direction. The coil laminate composed of bobbinless can be suitably held by force.

  Further, in the present invention, first, a coil laminated body having a coil sandwiched between an upper plate and a lower plate and wound with a wire material and laminated in a plurality of stages is formed, and then the upper plate and the lower plate are formed. By holding the upper plate and the lower plate by alternately winding the convex portions of the plates with a binding line, and forming a coil winding body made of a bobbinless coil, A coil molded body can be obtained by loading into the cavity of the mold apparatus and covering the coil winding body with molten resin.

  As described above, according to the present invention, after the coil laminate is formed and the upper and lower plates of the coil laminate are held by the tangling wire to form the coil winding, the coil winding is further melted with the molten resin. By performing the molding to cover with, a coil molded body including a coil winding body made of a bobbinless coil can be obtained simply and efficiently.

  According to the present invention, a coil winding system capable of easily and efficiently manufacturing a coil winding body made of a bobbinless coil can be obtained. Moreover, in this invention, the manufacturing method of the coil molded object which can obtain the coil molded object containing the coil winding body which consists of a bobbinless coil simply and efficiently can be obtained.

  Next, embodiments of the present invention will be described in detail with reference to the drawings as appropriate. 1 is an enlarged perspective view of a coil winding body manufactured by a coil winding system according to an embodiment of the present invention, FIG. 2 is a longitudinal sectional view of the coil winding body shown in FIG. 1, and FIG. FIG. 4 is a longitudinal sectional view taken along line IV-IV in FIG. 1, and FIG. 5 is a bottom view of the lower plate constituting the coil winding body. FIG. 6 is a partially enlarged perspective view showing a guide slope provided on the upper surface of the lower plate.

  First, the coil winding body 100 in which the wire 106 is wound by the coil winding system 10 shown in FIG. 7 will be described. In the winding stage of the wire 106 described later, the axial direction is the row direction of the wire 106 and the radial direction is the step direction.

  As shown in FIGS. 1 and 2, the coil winding body 100 includes an upper plate 102 (hereinafter referred to as an upper surface 102a of the upper plate 102) that is formed of a resin material and has a through hole 101 through which the upper jig 12 is inserted. , And a lower plate 104 formed of a resin material and having a through hole 103 (hereinafter referred to as an upper surface 104a and a lower surface 104b of the lower plate 104).

  Further, the coil winding body 100 is sandwiched between the upper plate 102 and the lower plate 104, and a coil laminated body 108 having a coil in which a wire (conductive wire) 106 is wound and laminated in a plurality of stages, Arcs that hold the upper plate 102 and the lower plate 104 by alternately winding the arc-shaped convex portions 114a and 114b of the upper plate 102 and the lower plate 104 that are non-superimposed along the vertical direction and arranged in a staggered pattern. And a barb 116. The coil inner peripheral surface 120 of the coil laminate 108 is not provided with any core material such as a coil bobbin, and is exposed to the outside.

  A first guide groove that guides the tangling wire 116 when the tangling wire 116 is entangled with the arc-shaped convex portions 114a and 114b protruding radially outward from the outer peripheral portions of the upper plate 102 and the lower plate 104. 122 is formed (see FIGS. 3 and 5). As shown in FIG. 4, the bottom surface of the inner wall of the first guide groove 122 is formed by a curved surface 123 having a slightly raised central portion as viewed in a longitudinal section. 114a and 114b are easily entangled and kept at an appropriate tension.

  The arcuate convex portions 114a and 114b are provided at five places on the upper plate 102 (see FIG. 3) and at six places on the lower plate 104 (see FIG. 5). Further, the first guide groove 122 formed in the arc-shaped convex portion 114a of the upper plate 102 is provided so as to open upward, while the first guide groove 122 formed in the arc-shaped convex portion 114b of the lower plate 104 is provided. They are provided so as to open downward, and are each configured to suitably hold the binding line 116.

  As shown in FIG. 1, a pin hole 119 a into which a first pin 17 a (see FIGS. 9 and 10) of the upper jig 12 to be described later is inserted is formed in the upper surface 102 a of the upper plate 102. The upper plate 102 is positioned at a predetermined position with respect to the upper jig 12 by inserting the pin 17a into the pin hole 119a.

  Further, as shown in FIG. 5, a pin hole 119b into which a second pin 17b (see FIGS. 9 and 11) of the lower jig 14 to be described later is inserted is formed in the lower surface 104b of the lower plate 104. The lower plate 104 is positioned at a predetermined position with respect to the lower jig 14 by inserting the second pin 17b into the pin hole 119b. The pin holes 119a and 119b do not penetrate the upper plate 102 or the lower plate 104, and are formed so as to close in the middle. Thereby, damage to the outer surface of the coil laminate 108 sandwiched between the upper plate 102 and the lower plate 104 is preferably prevented.

  As shown in FIG. 5, the lower plate 104 protrudes radially outward, and a first winding portion 110 a having a substantially L-shaped cross section around which a winding start portion of the wire 106 is wound, and a wire. A second winding portion 110b having a substantially L-shaped cross section is provided on which the winding end portion of 106 is wound. Note that a pair of terminal terminals 152a and 152b (see FIG. 29A), which will be described later, are caulked in the first winding portion 110a and the second winding portion 110b, respectively, in the next step. It is electrically connected to the winding start portion and winding end portion of the wire 106.

  Also, as shown in FIG. 5, a rectangular flat plate portion 124 is integrally formed between the outer peripheral surface of the lower plate 104 and the first and second winding portions 110a and 110b. On the flat plate portion 124 of the lower surface 104b of the lower plate 104, a winding start portion of the wire 106 wound around the first winding portion 110a is directed from the first winding portion 110a toward the outer periphery of the lower plate 104. A bent second guide groove 126 for guiding is formed.

  Further, as shown in FIGS. 2, 5, and 6, a cylindrical protrusion that slightly bulges in the axial direction (the upper surface 104 a and the lower surface 104 b of the lower plate 104) on the inner peripheral portion of the lower plate 104. A portion 128 is formed. As shown in FIG. 6, the upper surface 104 a of the lower plate 104 is a groove having a concave cross section extending in a tangential direction with respect to the cylindrical protrusion 128, and a winding start portion of the wire 106 is formed on the upper surface 104 a. A guide slope 130 is formed to guide from the outer peripheral portion of the lower plate 104 toward the inner peripheral portion. As shown in FIG. 20, the guide slope 130 is formed to have an inclined surface (groove bottom) inclined at a predetermined angle that is shallow on the inner peripheral portion side and gradually deeper toward the outer peripheral portion side.

  As shown in FIG. 6, one side wall 132 of the guide slope 130 substantially orthogonal to the inclined surface is spaced apart by a predetermined distance and bulges laterally toward the inclined surface, for example, two ribs 134. , 134 are formed. The ribs 134 and 134 come into contact with the wire 106 guided along the guide slope 130, so that, for example, when molding is performed in the next process, the molten resin passes through the guide slope 130 in the wire 130. As a result, it is possible to suitably prevent the molten resin from entering the coil inner peripheral surface 120. The number of ribs 134, 134 is not limited to a plurality, and one or more ribs may be used.

  Furthermore, as shown in FIG. 5, the arc-shaped convex portion 114 b of the lower plate 104 is formed with a notch portion 136 that locks the starting portion of the binding line 106, and other arc-shaped convex portions. 114b is formed with another notch 136 that locks the end portion of the binding line 106.

  As shown in FIG. 21, a third guide groove 138 is formed on the lower surface 102b of the upper plate 102 facing the lower plate 104. The guide groove 138 exhibits a function of guiding and aligning the wire 106 when the wire 106 is stacked in a plurality of stages and folded.

  Next, the coil winding system 10 according to the present embodiment will be described with reference to FIG.

  The coil winding system 10 includes an upper jig 12 that can be moved up and down along a vertical direction via a lifting mechanism (not shown), and a base (not shown) under the rotational driving action of the motor M along the arrow direction. And a coil winding device 15 including a lower jig 14 rotatably supported.

  Further, the coil winding system 10 is configured by assembling a nozzle 30 for feeding the wire 106 supplied from the wire supply source 17 to the coil winding device 15 and a plurality of linear actuators, and a guide (not shown). A triaxial actuator mechanism 32 for displacing the nozzle 30 in three XYZ directions orthogonal to each other under the guide action of a rail, and a tensioner device for applying an appropriate tension to the wire rod 106 fed from the nozzle 30 34. The nozzle 30, the triaxial actuator mechanism 32, and the wire supply source 17 function as wire supply means.

  As shown in FIGS. 9 and 10, the upper jig 12 includes an upper jig body 210 to which the upper plate 102 is attached and which holds the upper plate 102, and a claw portion 240 to be described later of the lower jig 14. And a taper body 220 that is inserted into the opening portion and expands the diameter of the claw portion 240 (divided claw).

  As shown in FIG. 10, the upper jig body 210 has a thick disk-like attachment in which a mounting surface 211 a (see FIGS. 13 to 15) having a shape corresponding to the upper surface 102 a of the upper plate 102 is formed on the lower surface. A seat 211 and an insertion rod portion 215 extending vertically downward from the center of the mounting seat 211 are provided.

  The mounting seat 211 is connected to a lifting mechanism (not shown) so as to be movable up and down, and a mounting surface 211 a that abuts the upper surface 102 a of the upper plate 102 is formed on the lower surface, and the upper plate 102 mounted on the mounting surface 211 a The first pin 17a for performing relative positioning is provided so as to protrude downward. The upper plate 102 is attached to the mounting surface 211a of the mounting seat 211 by an opening / closing claw 213 (see FIG. 13) that opens and closes in the radial direction.

  The insertion rod portion 215 is formed of a substantially cylindrical body that is inserted into a claw portion 240 described later of the lower jig 14, and an annular tapered surface 216 is formed at the lower end portion so as to be easily inserted.

  In addition, a key groove 217 into which a key 231 (see FIGS. 14 and 15) provided on the lower jig 14 is inserted is formed in the lower portion of the insertion rod portion 215 along the vertical direction. Thereby, the relative position in the circumferential direction of the insertion rod portion 215 (upper jig 12) and the lower jig 14 is positioned.

  Furthermore, a rotating lock groove 218 is formed on the lower peripheral surface of the insertion rod portion 215. When the upper jig 12 is inserted into the lower jig 14, the lock piece 232 of the lower jig 14 is locked. It is inserted into the groove 218 (see FIG. 15). Thereby, after the upper jig 12 is inserted into the lower jig 14, the upper jig 12 is prevented from being removed. A cylinder (not shown) is provided on the lower side of the lock piece 232. When the piston rod of the cylinder presses the lower end of the lock piece 232, the lock piece 232 is separated from the lock groove 218 so that the lock state is maintained. Canceled.

  The tapered body 220 is formed in a substantially inverted truncated cone shape that is inserted into the claw portion 240 after the lower portion of the insertion rod portion 215 is inserted into the claw portion 240, and the circumferential surface thereof is formed on the tapered surface 221. Yes. The tapered body 220 is formed with an insertion hole 222 penetrating along the axial direction, and the insertion rod portion 215 is inserted through the insertion hole 222.

  Further, two screw rods 223 and 223 are disposed above the taper body 220, and the two screw rods 223 and 223 are screwed into the two screw holes 214 and 214 of the mounting seat 211. . In this case, a nut 224 is fastened to the upper end of each screw rod 223, 223, and the nut 224 is locked to the mounting seat 211, so that the lower end position of the two screw rods 223, 223 is a predetermined height. It is provided to be adjustable.

  The lower ends of the screw rods 223 and 223 are in contact with the upper surface of the taper body 220. As a result, the taper body 220 has a predetermined height that is regulated by the height of the screw rods 223 and 223 with respect to the mounting seat 211. Is set. The tapered body 220 is guided in a vertical direction with respect to the upper jig body 210 by a key (not shown) and is held so as not to fall off.

  A compression coil spring 225 is interposed between the taper body 220 and the mounting seat 211, and when the upper jig 12 is inserted into the claw portion 240, the taper surface 221 of the taper body 220 is the taper surface of the claw portion 240. 240a (refer to FIG. 13) is provided so as to preferably come into contact.

  As shown in FIGS. 8 and 11, the lower jig 14 includes a lower jig body 230 having a substantially cylindrical shape, and a pedestal 230 a that is provided on an upper portion of the lower jig body 230 and includes a flange portion having an enlarged diameter. And an annular plate 261 inserted into a circular recess formed in the pedestal 230a, and first to third divided claws 241a to 241c supported so as to be displaceable along the radial direction of the annular plate 261. A claw portion 240 that expands in the radially outward direction by inserting the tapered body 220 of the upper jig 12, a wire rod 106 and a binding line 116 that protrude in a direction perpendicular to the axis of the lower jig body 230. And a pair of locking portions 212 and 212 for locking one end portion of the winding start.

  Further, as shown in FIG. 11, the lower jig 14 includes three radial springs 251 that press the first to third divided claws 241 a to 241 c of the claw portion 240 inward in the radial direction by a spring force, And six thrust springs 265 that press the claw portion 240 upward by a spring force.

  The lower jig body 230 is provided so as to be appropriately rotated by the motor M. The lower jig body 230 is provided with a key 231 that is inserted into the key groove 217 of the upper jig 12 and a lock piece 232 that engages with the lock groove 218 of the upper jig 12 (see FIG. 15). .

  The claw portion 240 has a cylindrical shape in a closed state, and has first to third divided claws 241a to 241c that are arcuate in a plan view when divided in the circumferential direction. The first to third divided claws 241 a to 241 c are slidably disposed along the radial direction, and are pressed radially inward by the radial spring 251.

  That is, when the upper jig 12 is not inserted into the claw portion 240, the first to third divided claws 241a to 241c are pressed radially inward by the spring force of the radial spring 251, and the claw The part 240 has a reduced diameter and is closed in a cylindrical shape. On the other hand, when the upper jig 12 is inserted into the claw portion 240, the first to third divided claws 241a to 241c are respectively displaced radially outward against the spring force of the radial spring 251; The claw portion 240 is expanded and opened.

  As shown in FIG. 13, the inner peripheral surface of each of the first to third divided claws 241 a to 241 c is formed into a tapered surface 240 a that gradually decreases in diameter toward the lower side, and below the tapered surface 240 a, The inner peripheral surface 240b has a constant inner diameter.

  As shown in FIG. 11, a circumferential groove 242 is formed along the circumferential direction on the lower side of the outer circumferential surface of each of the first to third divided claws 241a to 241c. Further, a narrow neck portion 247 is provided at a portion where the circumferential groove 242 of each of the first to third divided claws 241a to 241c is formed, and the neck portion 247 is a pair of protrusions 252a described later on the guide member 252. , 252a is slidably sandwiched. Further, a spring hole 242a is formed on the outer surface of the neck portion 247, and a radial spring 251 is mounted and positioned in the spring hole 242a.

  A first step portion 243 extending along the circumferential direction is formed on the upper side of the outer circumferential surface of each of the first to third divided claws 241a to 241c, and along the circumferential direction on the lower side of the outer circumferential surface. An extended second stepped portion 244 is formed. The first step portion 243 and the second step portion 244 are respectively provided at positions separated by a predetermined distance along the axial direction of the claw portion 240. In this case, when the claw portion 240 is opened, the first step portion 243 abuts on the inner peripheral side lower end surface 140 of the upper plate 102 (see FIG. 16), and the second step portion 244 has the claw portion 240 opened. At this time, the lower plate 104 is provided so as to come into contact with the inner circumferential upper end surface 142 (see FIG. 17).

  Furthermore, the lower end portion of each of the first to third divided claws 241a to 241c is provided with a locking flange 245 formed in an arc shape in a plan view, and the locking flange 245 includes a claw portion. When 240 is closed, it is provided to be locked to the raised portion 262 of the annular plate 261 (see FIG. 13).

  As shown in FIG. 7, when the upper jig 12 and the lower jig 14 are assembled coaxially, between the upper plate 102 and the lower plate 104 that are separated by a predetermined distance along the vertical direction, It is provided so that the peripheral surface of the claw portion 240 functioning as a winding portion around which the wire 106 is wound is exposed. The circumferential surface of the claw portion 240 is configured by arranging the circumferential surfaces of the first to third divided claws 241a to 241c apart from each other by a predetermined angle along the circumferential direction.

  In this case, as shown in FIG. 18, the circumferential surfaces of the first divided claw 241 a and the second divided claw 241 b extend in parallel along the horizontal direction and guide the wire 106 wound around the circumferential surface. A plurality of groove portions 246 are formed. Further, the peripheral surface of the third divided claw 241c is composed of a smooth surface 248 on which no uneven shape is formed. The smooth surface 248 smoothly performs transfer to the next row when the wire 106 is wound along the peripheral surface.

  As shown in FIG. 12, the three radial springs 251 are equiangular (every 120 degrees) in the circumferential direction via the guide member 252 on the upper surface of the base 230a of the lower jig body 230 in plan view. It is provided so as to be spaced apart and to be guided along the radial direction by a guide member 252.

  A pair of projecting portions 252a and 252a projecting substantially in parallel toward the first to third divided claws 241a to 241c are provided at one end portion along the axial direction of the guide member 252. The pair of projecting portions 252a , 252a is inserted into the circumferential groove 242 of each of the first to third divided claws 241a to 241c, and is provided so as to slidably sandwich the neck portion 247 of each of the first to third divided claws 241a to 241c. Accordingly, the first to third divided claws 241a to 241c are provided on the upper portion of the lower jig body 230 via the guide member 252 so as to be slidable along the radial direction.

  As shown in FIG. 11, a ring-shaped attachment plate 253 to which the lower plate 104 is attached is fixed on the guide member 252. A second pin 17b for positioning the lower plate 104 at a predetermined position with respect to the lower jig 14 is provided on the upper surface of the mounting plate 253, and a concave portion having a rectangular cross section in which the guide member 252 is mounted. 254 is formed.

  The six thrust springs 265 are constituted by, for example, compression coil springs or the like, and are attached to spring holes formed in the circular recesses of the base 230a of the lower jig body 230, and are equiangular along the circumferential direction ( They are arranged so as to be separated (every 60 degrees) (see FIG. 12).

  As shown in FIGS. 11 and 13, the annular plate 261 is disposed on the six thrust springs 265 and is uniformly supported by the six thrust springs 265. A claw portion 240 is disposed on the upper surface of the annular plate 261. That is, the six thrust springs 265 are provided so as to press the claw portion 240 upward via the annular plate 261.

  On the inner peripheral portion of the annular plate 261, a raised portion 262 formed thicker than the outer peripheral portion is provided. When the upper jig 12 is not inserted into the claw portion 240 and the claw portion 240 is closed, the locking flange 245 of the first to third divided claws 241a to 241c comes into contact with the raised portion 262 and is engaged. It is provided to be stopped. That is, the raised portion 262 is provided so as to function as a stopper that restricts the displacement of the first to third divided claws 241a to 241c inward in the radial direction in a state where the claw portion 240 is closed.

  The coil winding system 10 according to the present embodiment is basically configured as described above. Next, the operation of the coil winding system 10 will be described.

  First, an outline of a preparation process for winding the wire 106 will be described. As shown in FIG. 8, the upper jig 12 with the upper plate 102 attached and the lower jig 14 with the lower plate 104 attached. In a state of being separated coaxially, the upper jig 12 is lowered toward the lower jig 14 via a lifting mechanism (not shown), and the upper jig 12 and the lower jig 14 are assembled coaxially.

  In this case, the taper body 220 of the upper jig 12 is inserted into the claw portion 240 to press the first to third divided claws 241a to 241c in the radially outward direction, and the first to third divided claws 241a to 241c are By sliding outward in the radial direction, the assembly of the upper jig 12 and the lower jig 14 is completed. When the assembly of the upper and lower jigs 12 and 14 is completed, the upper and lower plates 102 and 104 are held at a predetermined interval, and preparation for winding the wire 106 around the peripheral surface (winding portion) of the claw portion 240 is completed. To do.

  Hereinafter, the assembly operation of the upper jig 12 and the lower jig 14 will be described in detail with reference to FIGS.

  As shown in FIG. 13, the upper plate 102 is attached to the lower surface (mounting surface 211a) of the mounting seat 211 of the upper jig 12 while the first pin 17a and the pin hole 119a are aligned. On the other hand, the lower plate 104 is attached to the upper surface 253a of the attachment plate 253 of the lower jig 14 while aligning the second pin 17b and the pin hole 119b.

  After the upper and lower plates 102 and 104 are mounted on the upper and lower jigs 12 and 14, respectively, the keys 231 of the lower jig 14 and the key grooves 217 of the upper jig 12 are aligned, and the upper and lower plates 102 and 104 are cured by a lifting mechanism (not shown). The tool 12 is lowered, and the insertion rod portion 215 of the upper jig 12 is inserted into the opening of the claw portion 240 of the lower jig 14.

  Thereafter, when the insertion rod portion 215 contacts the inner peripheral surface 240b of the first to third divided claws 241a to 241c, each of the first to third divided claws 241a to 241c resists the spring force of the radial spring 251. Then, it slides radially outward and the claw portion 240 begins to open (see FIG. 14).

  Further, when the tapered surface 221 of the tapered body 220 is lowered while contacting the tapered surface 240a of the first to third divided claws 241a to 241c, each of the first to third divided claws 241a to 241c further slides radially outward. . Next, when the locking flanges 245 of the first to third divided claws 241a to 241c come into contact with the inner peripheral surface 253b of the mounting plate 253 (see FIG. 15), the first to third divided claws 241a to 241c The radially outward slide is restricted.

  Here, since the first to third divided claws 241a to 241c are pressed by the respective thrust springs 265 via the annular plate 261, it is possible to press the upper part evenly. A gap G is formed between the second step 244 on the lower side of the third divided claws 241a to 241c and the inner peripheral upper end surface 142 of the lower plate 104 (FIG. 13, (See FIG. 14).

  When the upper jig 12 further descends and the lower surface 261a of the annular plate 261 contacts the upper surface 230a of the lower jig main body 230 as shown in FIG. 15, the lowering of the upper jig 12 stops. At this time, each of the first to third divided claws 241 a to 241 c slides downward against the pressing force of each thrust spring 265 as the upper jig 12 is lowered.

  Here, in the upper part P of the first to third divided claws 241a to 241c, as shown in FIG. 16, the lower end surface 140 on the inner peripheral side of the upper plate 102 has the first to third divided claws 241a to 241a. It abuts on the first step 243 on the upper side of 241c. On the other hand, in the lower part Q of the first to third divided claws 241a to 241c, as shown in FIG. 17, the inner peripheral side upper end surface 142 of the lower plate 120 is connected to the first to third divided claws 241a to 241c. The second stepped portion 244 on the lower side.

  In particular, in the lower portion Q, the first to third divided claws 241a to 241c are previously pressed upward by the spring force of the thrust spring 265 to form a gap G (FIGS. 13 and 14). 2) after the inner peripheral side upper end surface 142 of the lower plate 104 is positioned directly below the second step portion 244 on the lower side of each of the first to third divided claws 241a to 241c. 244 contacts the inner peripheral upper end surface 142.

  As a result, for example, the trouble that the outer peripheral surface of the split claw (not shown) that does not have the thrust spring 265 and slides only on the radially outer side contacts the inner peripheral surface 103a (see FIG. 17) of the lower plate 104 is prevented. Is done.

  As described above, the upper jig 12 is coaxially assembled to the lower jig 14, and the lock piece 232 of the lower jig 14 is engaged with the lock groove 218 to be locked.

  When the upper jig 12 is assembled to the lower jig 14 as described above, as shown in FIG. 15, the lower surface (mounting surface 211 a) of the mounting seat 211 in the upper jig 12 and the attachment in the lower jig 14. The axial length L between the upper surface 253a of the plate 253 is set to a predetermined value. Further, the outer peripheral position where the diameter of each of the first to third divided claws 241a to 241c is expanded, that is, the radial length D is also set to a predetermined value.

  Here, the respective axial height positions of the upper first stepped portion 243 and the lower second stepped portion 244 formed in the first to third divided claws 241a to 241c are within the upper plate 102. The position is set at a position where a compressive load is applied to the circumferential lower end surface 140 and the inner circumferential upper end surface 142 of the lower plate 104.

  As a result, the upper plate 102 is between the lower surface (mounting surface 211a) of the mounting seat 211 and the first step portions 243 of the first to third divided claws 241a to 241c, and the lower plate 104 is the upper surface of the mounting plate 253. Between 253a and the 2nd level | step-difference part 244 of 1st-3rd division | segmentation nail | claw 241a-241c, it clamps in a predetermined position, ie, is restrained.

  More specifically, the upper plate 102 is applied with a pressing force A2 that presses the upper surface of the upper plate 102 vertically downward from the lower surface (mounting surface 211a) of the mounting seat 211 (see FIG. 15). At the same time, a compressive load (pressing force A3, FIG. 15, FIG. 16) presses the inner peripheral side lower end surface 140 of the upper plate 102 from the first step portion 243 of the first to third divided claws 241a to 241c upward in the axial direction. Reference).

  Further, a pressing force A6 is applied to the lower plate 104 from the upper surface 253a of the mounting plate 253 to press the lower surface of the lower plate 104 vertically upward (see FIG. 15), and at the same time, the first to third divisions are performed. A compression load (pressing force A5, see FIGS. 15 and 17) is applied to press the inner peripheral side upper end surface 142 of the lower plate 104 downward in the axial direction from the second stepped portion 244 of the claws 241a to 241c. In the radial direction, a predetermined clearance is formed between the first to third divided claws 241a to 241c and the through hole 103 of the lower plate 104 (see FIG. 17).

  Thus, in a state where the upper jig 12 and the lower jig 14 are assembled, the upper plate 102 and the lower plate 104 are restrained at predetermined positions with respect to the opened claw portion 240, and the upper plate 102 and the lower plate A predetermined width is set between the distance 104 and the distance 104 (the distance between the upper and lower sides).

  In other words, since the outer peripheral surface of the claw portion 240 is a core portion, the upper plate 102 is an upper flange portion, and the lower plate 104 is a lower flange portion, the same structure as a bobbin having an upper flange portion and a lower flange portion, That is, a virtual bobbin can be formed, and the wire 106 can be easily wound. As a result, the wire 106 is wound between the upper plate 102 and the lower plate 104, and the coil stack 108 in which the winding shape is not disturbed, that is, the wire 106 is aligned in the axial direction can be obtained.

  Next, a method for winding the wire 106 between the upper and lower plates 102 and 104 held by the upper and lower jigs 12 and 14 as described above will be described.

  First, in a state where the motor M is in the deenergized state and the upper and lower jigs 12 and 14 assembled coaxially are stationary, the nozzle 30 is displaced under the driving action of the triaxial actuator mechanism 32, and the nozzle 30 is moved away from the nozzle 30. After one end of the winding start of the fed wire 106 is locked to the locking portion 212 of the lower jig main body 230, it is provided on the left side of the lower plate 104 as shown in FIG. Further, the outer circumferential surface of the first winding portion 110a is wound once clockwise from the lower side (see arrows a1 and a2). In addition, since moderate tension | tensile_strength is provided to the wire 106 delivered from the nozzle 30 by the tensioner apparatus 34, it can prevent suitably that the wound wire 106 is frayed.

  Subsequently, the nozzle 30 is displaced along the lateral direction under the driving action of the triaxial actuator mechanism 32, and the second guide groove 126 formed on the lower surface of the second winding portion 110 b on the right side toward the lower plate 104. After the wire rod 106 is inserted along (see the partial perspective view of FIG. 19A), the wire rod 106 is guided along the guide slope 130 formed on the upper surface 104a of the lower plate 104 as indicated by an arrow a3. As described above, the wire 106 is led out from the outer peripheral portion of the lower plate 104 toward the inner peripheral portion.

  When the wire 106 is guided along the inclined surface of the guide slope 130 and reaches the smooth surface 248 (lowermost part) of the third split claw 241c, the motor M is energized to move the upper and lower jigs 12 and 14 in the direction of the arrow. Are integrally guided along the grooves 246 of the first and second divided claws 241a and 241b to reach the smooth surface 248 of the third divided claws 241c again (see FIG. 20). At that time, since the peripheral surface of the third divided claw 241c is formed by the smooth surface 248 and does not restrict the winding direction of the wire 106, the wire 106 can be smoothly transferred to the next row. .

  Further, the nozzle 30 is displaced upward, and the wire 106 is wound a plurality of times along the row direction (axial direction) of the peripheral surfaces of the first to third divided claws 241a to 241c, as indicated by an arrow a4. (See FIG. 19B), the nozzle 30 reciprocates along the axial direction, whereby the wire 106 is sequentially laminated along the radial direction of the peripheral surface of the claw 240 (FIG. 19C). )reference).

  The upper and lower jigs 12 and 14 rotate integrally, and the wire 30 is fed while the nozzle 30 reciprocates between the lower plate 104 and the upper plate 102 a plurality of times to form a coil stack 108 having a plurality of stages. After that, in a state where the rotation of the upper and lower jigs 12 and 14 is stopped, as shown by arrows a5 to a7 in FIG. Then, after winding the outer peripheral surface of the right second fastening portion 110b in the clockwise direction from the upper side, the winding end portion of the wire rod 106 is cut by a cutter means (not shown).

  Thus, the upper jig 12 and the lower jig 14 are assembled coaxially, and the upper plate 102 and the lower plate 104 are spaced apart from the claw portion 204 by a predetermined distance. Between the plate 102 and the lower plate 104, the coil stack 108 in which the wire 106 is wound and aligned in the axial direction can be obtained (see block E1 in FIG. 30).

  Moreover, the winding start portion and the winding end portion of the coil laminate 108 exposed to the outside are respectively wound around the adjacent first winding portion 110a and second winding portion 110b, and the flat plate portion of the lower plate 104 By separating them on the upper and lower surfaces of 124 and arranging them in a cross shape (cross), it is possible to ensure isolation of the coil laminate 108 including the winding start portion and the winding end portion.

  Next, how to bind the binding wire 116 that holds the coil laminate 108 made of a bobbinless coil along the vertical direction will be described with reference to FIG. In addition, since the point at which one end portion of the binding wire 116 starts to be locked by the locking portion 212 is the same as the case where the coil laminated body 108 is formed by winding the wire 106, the description thereof will be given. Omitted. Further, as the binding wire 116, the wire 106 (conductive wire) fed from the nozzle 30 is described below, but the present invention is not limited to this, and a wire other than the conductive wire is used. Also good.

  As shown by the arrows c1 to c3, the winding start portion of the binding wire 116 is wound around the outer peripheral surface of the arc-shaped convex portion 114b of the lower plate 104 in the clockwise direction from the lower side, and then the binding wire 116 is wound. Is engaged with the first guide groove 122 (see FIG. 3) of the arc-shaped convex portion 114a of the upper plate. At that time, the arc-shaped convex portion 114 b of the lower plate 104 is formed with a notch 136 that locks the tangling start portion of the tying wire 116, so that the tangling wire 116 is formed by the notch 136. The entanglement starting portion is smoothly locked.

  Subsequently, in a state where the upper and lower jigs 12 and 14 are integrally rotated along the circumferential direction under the driving action of the motor M, the nozzle 30 is reciprocated in the vertical direction, as indicated by arrows c4 to c17. The first guide grooves 122 of the arc-shaped convex portions 114b of the lower plate 104 and the first guides of the arc-shaped convex portions 114a of the upper plate 102 that are non-overlapping along the vertical direction and are alternately arranged along the circumferential direction. The tangling line 116 is sequentially tangled along the groove 122. The motor M is controlled by a controller (not shown), and the tension of the tangled wire 116 tangled along the arc-shaped convex portions 114a and 114b of the upper and lower plates 102 and 104 is appropriately controlled by normal rotation and reverse rotation. Set moderately.

  In this case, the arc-shaped convex portions 114a of the upper plate 102 and the arc-shaped convex portions 114b of the lower plate 104, which are engaging portions of the binding line 116, are alternately arranged in a staggered manner along the circumferential direction. Therefore, it is possible to suitably prevent displacement of the upper and lower plates 102 and 104 with respect to the rotation direction.

  Further, a binding line 116 entangled between the upper and lower plates 102 and 104 extends substantially parallel to the axial direction of the coil laminate 108. For this reason, for example, when the outer surface of the coil winding body 100 is molded with molten resin in the next step, the filling direction of the molten resin injected from the gate of the mold apparatus described later is parallel to the axial direction. By setting to, an excessive load is not applied to the binding wire 116 by the molten resin, and a good resin is maintained while the coil laminated body 108 is maintained by the binding wire 116. A molded body (see FIG. 29B) can be obtained.

  The arc-shaped convex portions 114a and 114b of the upper and lower plates 102 and 104 are alternately wound along the vertical direction by the binding line 116, and the binding line 116 is drawn along the circumferential direction of the upper and lower plates 102 and 104. As shown by c18 to c20, after winding the outer peripheral surface of the other arc-shaped convex portion 114b of the lower plate 104 once in the clockwise direction, the end portion of the binding line 116 is cut by a cutter means (not shown). . At this time, the other arc-shaped convex portion 114 b of the lower plate 104 is formed with a notch 136 that locks the end portion of the binding line 116, so that the notch 136 entangles it. The end portion of the line 116 is smoothly locked.

  In this way, after the coil winding body 100 in which the binding wire 116 is entangled on the outer peripheral surfaces of the upper and lower plates 102 and 104 is configured, the upper jig 12 is moved to the lower jig 14 via a lifting mechanism (not shown). As a result, the coil winding body 100 is taken out and conveyed to the next step.

  In the present embodiment, the upper and lower plates 102 and 104 arranged at a predetermined interval are held by the upper and lower jigs 12 and 14, and the wire 106 is wound around the circumferential surface of the claw portion 240 provided on the lower jig 104. A coil winding body 100 made of a bobbinless coil can be easily and efficiently formed (see block E2 in FIG. 30).

  Further, in the present embodiment, the coil laminate 108 aligned between the upper and lower plates 102 and 104 can be preferably kept in isolation, and the coil laminate 108 exposed to the outside starts to be wound. When the portion and the winding end portion are wound around the first winding portion 110a and the second winding portion 110b that are separated in the left-right direction, respectively, and are separated into the upper and lower surfaces of the flat plate portion 124 and pulled out in a crossing manner. The isolation property of the coil laminate 108 can be reliably ensured.

  In other words, in this embodiment, the winding start portion of the coil laminate 108 is pulled out along the lower surface 104b of the flat plate portion 124 of the resin lower plate 104 via the second guide groove 126, and the coil laminate 108 is used. A flat plate formed of a resin material between the winding start portion and the winding end portion is drawn out so as to intersect the winding start portion along the upper surface 104a of the flat plate portion 124 of the lower plate 104. Isolation can be reliably maintained by interposing the part 124 in a non-contact state.

  As mentioned above, although one Embodiment of this invention was described, this invention is not limited to Embodiment, For example, it can change as follows in the range which does not deviate from the meaning of this invention.

  In the above-described embodiment, the claw portion 240 includes the first to third divided claws 241a to 241c. However, the number of the divided claws is not limited to this, and may be two, or four or more. Further, the number of radial springs 251 and thrust springs 265 may be changed as appropriate.

  In the above-described embodiment, the configuration in which the thrust spring 265 is a compression coil spring has been exemplified. However, for example, a rubber member formed of an appropriate rubber may be used. The same applies to the radial spring 251.

  In the above-described embodiment, the upper jig 12 includes the tapered body 220 and the lower jig 14 includes the claw portion 240. However, the functions of the upper jig 12 and the functions of the lower jig 14 are reversed. The upper jig 12 may be provided with a claw portion 240, and the lower jig 14 may be provided with a tapered body 220.

  Next, a process for obtaining a coil molded body by molding the coil winding body 100 formed in the above process with a resin material will be described below. FIG. 23 is a longitudinal sectional view of a schematic configuration of a mold apparatus for performing molding, and FIG. 24 is a schematic configuration of a state in which a molding object is loaded in a cavity of the mold apparatus and clamped. It is a longitudinal cross-sectional view.

  First, the molded object 300 in which the outer surface excluding the inner peripheral surface is coated (molded) with a resin material will be described. As shown in FIG. 29A, the molded body 300 is sandwiched between an upper side first plate 104 and a lower side second plate 102 respectively formed of a resin material. Is connected to a coil winding body 100 having a coil wound around and stacked in a plurality of stages, and a pair of winding portions 110a and 110b projecting radially outward of the first plate 104, and electrically connected to the coil. And the first plate 104 and the arc-shaped convex portions 114b of the second plate 102 that are spaced apart from each other by a predetermined distance along the vertical direction are alternately entangled with each other. A tie wire 116 for holding the first plate 104 and the second plate 102.

  In the molded body 300, the lower plate 104 constituting the coil winding body 100 shown in FIG. 1 is an upper first plate 104, and the upper plate 102 is configured as a lower second plate 102. The to-be-molded body 300 is arranged in a state where the top and bottom of the coil winding body 100 are reversed. In addition, the same components are denoted by the same reference numerals and described below.

  The terminal unit 150 includes a first terminal terminal 152a that is electrically connected to a winding start portion of the wire rod 106, and a second terminal terminal 152b that is electrically connected to a winding end portion of the wire rod 106. The coil inner peripheral surface 120 of the coil winding body 100 is not provided with any core material such as a coil bobbin, and is exposed to the outside.

  The first plate 104 is located between the adjacent arc-shaped convex portions 114b and spaced apart at an equal angle along the circumferential direction from the coil outer circumferential surface 121 (see FIG. 23) by a predetermined length in the radially outward direction. Three protruding portions 154 that protrude are provided. Each of the protrusions 154 functions as a molten resin receiving portion located immediately below the terminal end of each gate when molten resin is injected into the cavity 430 from a plurality of gates of the upper mold 412 as described later. In addition, the molten resin received by the protrusions 154 is urged to flow into the thin portion molding space 444 described later (see FIG. 28).

  Next, as shown in FIG. 23, the mold apparatus 410 includes an upper mold 412 that can be moved up and down via a lifting mechanism (not shown), a lower mold 414 that is fixed on a base (not shown), and not shown. A pair of split types provided with protrusions 418 that are provided so as to be movable back and forth in the lateral direction via a displacement mechanism and function as a nesting for forming a hollow coupler portion 502 (see FIG. 29B) described later. 420a, 420b. The pair of split molds 420a and 420b may be configured integrally without being divided.

  Further, the mold device 410 is fitted in the hole of the upper mold 412 and abuts on the upper surface of the upper side of the first plate 104 in the vicinity of the upper peripheral edge to press the coil winding body 100 downward. In addition, the first protrusion 424 bulging and forming the annular protrusion 422 to be sealed and the hole of the lower die 414 are mounted on the lower surface of the second plate 102 on the lower side and face the resin molded body 500 (FIG. 29). (B)) a second piece member 428 in which an annular projection 426 for forming an annular groove (not shown) for mounting a seal is formed on the bottom surface, and the second piece member 428 is fitted in the second piece member 428. And a core member 432 that forms a cavity 430 (see FIG. 24) between the upper mold 412 and the lower mold 414. The mold device 410 is provided with a gas vent passage (not shown) communicating with the cavity 430.

  The upper mold 412 is provided with a plurality of gates that are connected to a molten resin supply source (not shown) including a plastic injection molding machine or the like and discharge (inject) the molten resin toward the cavity 430. As shown in FIG. 27, the plurality of gates are arranged at equal angles along the circumferential direction of the coil winding body 100, and cover the outer circumferential surface of the coil winding body 100 and both end surfaces in the axial direction. The first to third gates 434a to 434c for forming the resin sealing body 504 (see FIG. 29B) and the coupler portion 502 formed of a cylindrical body for housing the first and second terminal terminals 152a and 152b are formed. And a fourth gate 434d.

  In this case, as shown in FIGS. 24 and 27, the first to third gates 434a to 434c are in positions corresponding to the protrusions 154 of the first plate 412 in the clamped state. It is disposed at a position immediately above or substantially directly above the protrusion 154. 27 is a plan view of the clamped mold device 410 as viewed from above, and the positions along the vertical direction of the first to third gates 434a to 434c and the protrusions 154 of the first plate 104 are shown. In order to clarify the relationship, the protrusion 154 of the first plate 104 disposed in the cavity 430 is indicated by a solid line for convenience.

  The lower mold 414 is provided with a plurality of ejector pins 436 for taking out the resin molded body 500 from the cavity 430 by pressing the resin molded body 500 in which the molten resin is solidified upward (FIG. 26). reference). The ejector pin 436 is provided so as to be displaceable in the vertical direction by a driving action of an actuator (not shown).

  The core member 432 is in contact with the inner peripheral surface 160 of the first plate 104 on the upper side, and has a cylindrical portion 438 that performs positioning and sealing functions with the inner peripheral surface 160 of the first plate 104, and a lower side. A skirt portion 440 composed of an annular enlarged portion that contacts the inner peripheral surface 162 of the second plate 102 and performs positioning and sealing functions with the inner peripheral surface 162 of the second plate 102, and a second piece member 428 An annular step portion 439 that is formed on the lower side of the adjacent skirt portion 440 and presses the lower surface near the bent portion side of the second plate 102 toward the upper side is provided.

  The diameter (outer diameter) D1 of the cylindrical portion 438 of the core member 432 between the first plate 104 and the second plate 102 along the vertical direction and facing the coil inner peripheral surface 120 is set in the coil. It is set smaller than the inner diameter D2 of the peripheral surface 120 (D1 <D2). Therefore, as shown in FIG. 24, in a state where the molded object 300 is loaded in the cavity 430 and clamped, the core member 432 and the coil are held in a non-contact state, and the cylindrical portion 438 of the core member 432 A clearance 442 is formed between the outer diameter surface and the coil inner peripheral surface 120.

  In the present embodiment, the upper mold 412 is provided so as to be movable up and down with respect to the lower mold 414. However, the present invention is not limited to this, and the upper mold 412 and the lower mold 414 can be relatively separated from each other. What is necessary is just to be provided.

  The mold apparatus 410 for performing the molding method is basically configured as described above. Next, the function and effect will be described.

  First, as shown in FIG. 23, after the molded object 300 (see FIG. 29A) is loaded into the cavity 430 of the mold apparatus 410, the upper mold 412 and the first mold are connected via a lifting mechanism (not shown). The piece member 424 is lowered integrally, and the pair of split molds 420a and 420b are displaced via a displacement mechanism (not shown) to obtain a mold clamping state.

  In the mold clamping state, as shown in FIGS. 24 and 27, the terminal portions 446 of the first to third gates 434a to 434c and the protrusions 154 of the first plate 104 have a corresponding positional relationship along the vertical direction. The terminal portions 446 of the first to third gates 434a to 434c are located directly above or substantially above the protrusions 154. Further, in the mold clamping state, for forming an annular thin portion in which the vertical dimension is small and the radial dimension is narrow between the bottom wall of the upper mold 412 and the upper surface of the first plate 104. A space 444 is provided. The thin portion molding space 444 constitutes a part of the cavity 430 and forms a thin portion 512 constituting the bottom surface of the annular recess 506 formed on the outer end surface (upper surface) of the resin molded body 500 described later. Is to do.

  After being clamped, a molten resin supply source (not shown) is energized to inject the molten resin from the first to fourth gates 434a to 434d (see FIG. 25). The molten resin discharged from the terminal portions 446 of the first to third gates 434a to 434c is received by the protruding portion 154 of the first plate 104 functioning as a molten resin receiving portion, and the first wall 104 and the first wall of the upper die 412 The flow of the molten resin into the thin portion molding space 444 formed between the upper surface of the plate 104 is promoted and the molten resin is smoothly filled into the thin portion molding space 444, and the molding is performed. It flows downward along a cavity 430 formed between the outer periphery of the body 300 and the side wall of the lower mold 414 (see FIG. 28). The filling direction of the molten resin is parallel to the axial direction of the coil winding body 100 and is gradually filled from the lower side of the cavity 430 toward the upper side.

  In other words, if the protrusion 154 of the first plate 104 is not provided immediately below the terminal end 446 of the first to third gates 434a to 434c, the terminal end 446 of the first to third gates 434a to 434c Since there is nothing that accepts the discharged molten resin, the molten resin only flows downward along the cavity 430, and from the terminal portion 446 of the first to third gates 434 a to 434 c in the lateral direction ( It becomes difficult for the molten resin to flow into the thin portion molding space 444 extending in the direction perpendicular to the discharge direction of the molten resin, and a short mold occurs due to an insufficient filling amount in the thin portion molding space 444. There is a risk.

  However, in the present embodiment, the protrusion 154 that functions as the molten resin receiving portion is arranged on the outer peripheral edge of the first plate 104 so as to be positioned directly below the terminal portion 446 of the first to third gates 434a to 434c. The molten resin flow direction is changed by the protruding portion 154 and the lateral direction (direction orthogonal to the molten resin discharge direction) from the terminal portion 446 of the first to third gates 434a to 434c is provided. The molten resin can flow into the thin-walled portion 444, and the molten resin is smoothly filled into the thin-walled portion molding space 444, whereby the occurrence of the short mold can be suitably prevented.

  In this case, the annular protrusion 422 of the first piece member 424 comes into contact with the upper surface of the first plate 104 in the vicinity of the inner peripheral edge portion and presses the molded body 300 downward, so that the molten resin enters the cavity 430. When filled along, the phenomenon that the first plate 104 and the second plate 102 are lifted upward can be suitably prevented.

  Further, the inner peripheral surface 160 of the first plate 104 contacts the outer diameter surface of the cylindrical portion 438 of the core member 432 to form a first seal portion, and the first seal portion is formed with respect to the skirt portion 440 of the core member 432. The inner peripheral surface 162 of the two plates 102 contacts to form a second seal portion. Further, since the first plate 104 on the upper side and the second plate 102 on the lower side are respectively positioned at predetermined positions by the columnar portion 438 and the skirt portion 440 of the core member 432, the coaxiality (coaxial accuracy) of the molded body 300 is determined. Becomes better. Accordingly, when the molten resin is filled along the cavity 430, the first and second seal portions formed by the inner peripheral surfaces 160 and 162 of the first and second plates 104 and 102 are melted by the coil inner peripheral surface 120. Intrusion of the resin is suitably prevented, and filling of the molten resin into the molded body 300 can be satisfactorily achieved while ensuring coaxiality.

  Moreover, as described above, the clearance 442 is set between the outer diameter surface of the cylindrical portion 438 of the core member 432 and the coil inner peripheral surface 120. As a result, the wire 106 laminated on the coil inner peripheral surface 120 is suitably protected without being damaged at the time of loading into the cavity 430 or by the flow of the molten resin.

  Furthermore, in the present embodiment, by providing the first piece member 424 having the annular protrusion 422 that presses the vicinity of the inner peripheral surface of the first plate 104 downward, the sealing action of the first seal portion is shared. It is possible to further improve the sealing function. Further, by providing the core member 432 with an annular step 439 that presses the lower surface of the second plate 102 in the vicinity of the bent portion toward the upper side, the sealing function is achieved in cooperation with the sealing action of the second seal portion. Can be further improved.

  After the molten resin injected from the first to fourth gates 434a to 434d has been filled into the cavity 430, the molten resin is solidified to remove the coil inner peripheral surface 120 of the coil winding body 100. A resin molded body (coil molded body) 500 in which both end surfaces and outer peripheral surfaces in the axial direction are molded of a resin material is formed (see block E3 in FIG. 30). Therefore, the plurality of ejector pins 436 are raised under the driving action of an actuator (not shown) to press the resin molded body 500 upward, whereby the resin molded body 500 can be easily taken out from the cavity 430 of the mold apparatus 410. Then, it can be transferred to the next process.

  As shown in FIG. 29B, an annular recess 506 for mounting a seal member (not shown) is formed on the upper surface (outer end surface along the axial direction) of the resin molded body 500, and the annular recess 506 is formed. A plurality of substantially small circular gate traces 510 are formed on the annular convex edge 508 in the radial outward direction. Therefore, since the gate trace 510 is not formed in the annular recess 506 serving as the seal surface, the seal function can be suitably exhibited by the seal surface formed of a smooth surface without unevenness.

  In other words, by arranging the positions of the first to third gates 434a to 434c formed in the mold apparatus 410 in a radially outward direction from the thin portion forming space portion 444, the thin portion forming space portion 444 is formed. A gate mark 510 is formed on the outer peripheral side of the thin portion 512 of the resin molded body 500 formed by the above. Therefore, since the gate trace 510 is not formed on the thin portion 512 serving as the sealing surface, the sealing function can be suitably exhibited by the sealing surface that is smooth and has no unevenness.

  Further, a thin portion 512 constituting the bottom surface of the annular recess 506 is formed on the outer end surface along the axial direction of the resin molded body 500. The thin portion 512 is formed by solidifying the molten resin filled in the thin portion molding space 444 which is a part of the cavity 430. As described above, the occurrence of short mold, sink, etc. Therefore, it is possible to obtain a good molding surface in which is suitably prevented.

It is an expansion perspective view of a coil winding object manufactured by a coil winding system concerning an embodiment of the present invention. It is a longitudinal cross-sectional view of the coil winding body shown in FIG. It is the top view which looked at the upper plate which comprises the said coil winding body from upper direction. It is a longitudinal cross-sectional view along the IV-IV line of FIG. It is a bottom view which shows the lower surface of the lower plate which comprises the said coil winding body. It is a partial expansion perspective view which shows the guide slope provided in the upper surface of the said lower plate. 1 is a schematic configuration perspective view of a coil winding system according to an embodiment of the present invention. It is a partially omitted exploded perspective view of a coil winding apparatus constituting the coil winding system. It is a disassembled perspective view of the said coil winding apparatus. It is a disassembled perspective view of the upper jig | tool which comprises the said coil winding apparatus. It is a disassembled perspective view of the lower jig | tool which comprises the said coil winding apparatus. It is a partial cross section top view of the said lower jig | tool, and a mounting plate is abbreviate | omitted. It is a longitudinal cross-sectional view which shows the state before inserting the said upper jig | tool into a lower jig | tool. It is a longitudinal cross-sectional view which shows the state in the middle of inserting the said upper jig | tool in the lower jig | tool. It is a longitudinal cross-sectional view which shows the state after inserting the said upper jig | tool in a lower jig | tool. FIG. 16 is an enlarged longitudinal sectional view of a part P of FIG. 15. FIG. 16 is an enlarged longitudinal sectional view of a part Q in FIG. 15. It is the figure which expanded the condition where the wire is wound around the nail | claw part in the circumferential direction. (A)-(c) is a partially-omission perspective view which shows the order of the winding method which winds a wire around the nail | claw part provided between the upper and lower plates, respectively. The peripheral surface of the 1st-3rd division | segmentation nail | claw which comprises the said nail | claw part is represented on a plane for convenience, and it is a partially notched side view which shows the state by which a wire is wound around the said 1st-3rd division | segmentation claw. is there. It is a fragmentary longitudinal cross-section which shows the state by which a wire is folded and laminated | stacked. It is the perspective view which showed the state where the circular-arc-shaped convex parts each formed in the outer peripheral part of an up-and-down plate were entangled with a tangling line in time series. It is a schematic structure longitudinal cross-sectional view of the metal mold | die apparatus which implements the resin molding method which molds a coil winding body. FIG. 24 is a schematic longitudinal sectional view of a configuration in which a molding target is loaded in a cavity of the mold apparatus shown in FIG. 23 and clamped. It is a schematic structure longitudinal cross-sectional view of the state which poured molten resin from the gate in the said state clamped. It is a schematic structure longitudinal cross-sectional view of the state which the mold was opened and the resin molding was taken out. It is a top view of the metal mold apparatus which shows the positional relationship of the projection part of a 1st plate, and a gate. It is the elements on larger scale which show the state where the molten resin inject | poured from the gate is urged | promoted by the protrusion part to the thin part molding space part. (A) is a perspective view which shows a to-be-molded body, (b) is a perspective view of the molded resin molding. It is a block diagram which shows the manufacturing process of a coil molded object.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Coil winding system 12 Upper jig | tool 14 Lower jig | tool 15 Coil winding apparatus 17 Wire material supply source 34 Tensioner apparatus 100 Coil winding body 102 Upper plate 104 Lower plate 106 Wire material 108 Coil laminated body 116 Tying wire 114a, 114b Circle Arc-shaped convex part 240 Claw part 241a-241c 1st-3rd division | segmentation claw 410 Mold apparatus 430 Cavity 500 Resin molded object

Claims (3)

A coil winding device in which an upper jig to which an upper plate is attached and a lower jig to which a lower plate is attached are provided so as to be relatively displaceable;
Wire supply means for supplying a wire wound as a coil to the coil winding device;
A tensioner device that applies a predetermined tension to the wire supplied to the coil winding device;
With
The coil winding device has a winding portion between the upper plate and the lower plate and around which the wire is wound, and the upper jig and the lower jig are assembled coaxially. A coil winding system comprising a claw portion including a plurality of divided claws that slide in a radial direction when pressed. The coil winding system of claim 1, wherein
A coil winding body is manufactured by the coil winding system,
The coil winding body includes a coil laminated body having a coil sandwiched between the upper plate and the lower plate and wound with a wire and laminated in a plurality of stages, and convex portions of the upper plate and the lower plate A coil winding system characterized by having a binding wire that holds the upper plate and the lower plate by alternately winding them together. Forming a coil laminated body having a coil sandwiched between an upper plate and a lower plate and wound with a wire and laminated in a plurality of stages;
A step of holding the upper plate and the lower plate by alternately winding the convex portions of the upper plate and the lower plate with a binding line, and forming a coil winding body made of a bobbinless coil;
Loading the coil winding body into a cavity of a mold apparatus and coating the coil winding body with a molten resin to obtain a coil molded body;
The manufacturing method of the coil molded object characterized by having.

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