JP2009289859A - Method of manufacturing molded coil - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a molded coil of which the space factor and heat dissipation property do not deteriorate and which has good manufacturing efficiency by pressing a coil disposed in a metal mold and correcting the shape, and then molding a surface of the coil with a resin. <P>SOLUTION: The method of manufacturing the molded coil includes a coil arranging step of arranging the coil 10 in the metal mold 100, a coil shape correcting step of correcting the coil shape by pressing side surfaces 10b and 10c of a coil side and a coil end from outside the coil 10 disposed in the metal mold 100, and a resin injecting step of injecting the resin to the surface of the coil 10 disposed in the metal mold 100. The molded coil is manufactured by injecting the resin to the surface of the coil 10 in the resin injecting step after correcting the coil shape in the coil shape correcting step. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method of manufacturing a molded coil in which the surface of a coil is resin-molded after correcting the shape of the coil arranged in a mold.

Conventionally, as an invention for preventing a shift between conductive wires constituting a coil, for example, there is one shown in Patent Document 1 below. Patent Document 1 is an invention relating to a winding structure of an electric motor, a winding method thereof, and a winding device thereof, and has an advantage of suppressing a deviation at the time of winding of a conducting wire.
JP 2007-244115 A

  However, the invention related to the winding structure of the electric motor, the winding method thereof, and the winding apparatus shown in Patent Document 1 prevents the gap between the conductors by winding the conductor wound around the teeth portion of the core with high accuracy. However, the configuration of the wound coil itself is not integrally configured to prevent deviation between the conducting wires, and there is a problem in manufacturing efficiency.

  Therefore, the present invention solves the above-mentioned conventional problems, presses the coil arranged in the mold, corrects the shape, and then resin molds the surface of the coil, thereby reducing the space factor and heat dissipation. It is another object to provide a method for producing a molded coil with high production efficiency.

  The method for producing a molded coil according to the present invention is a method for producing a molded coil in which the surface of a coil is resin-molded by injecting resin into a mold in which the coil is disposed, and at least the coil is used as a mold. A coil arrangement step to be arranged, a coil shape correction step of correcting the coil shape by pressing the coil side surface from either the inside or the outside of the coil arranged in the mold, and the surface of the coil arranged in the die And a resin injection step of injecting resin into the first feature.

  According to the first feature of the present invention, the coil shape is obtained by pressing the coil side surface from either the inside or the outside of the coil arranged in the die, and the coil arranging step of arranging at least the coil in the die. The coil shape correcting step for correcting the resin and the resin injecting step for injecting resin into the surface of the coil arranged in the mold are used, so that the coil is surely arranged in the die by the coil arranging step. Can do. Further, the coil shape can be corrected by reliably pressing the coil side surface by the coil shape correcting step. Further, the resin can be reliably injected into the surface of the coil by the resin injection step.

  In addition to the first feature of the present invention, the method for manufacturing a molded coil according to the present invention further includes a mechanism that allows the coil side surface pressing in the coil shape correcting step to advance and retract with respect to the resin injection space in the mold. The second feature is that it is performed by the coil pressing means.

  According to the second feature of the present invention, in addition to the function and effect of the first feature of the present invention, the pressing of the coil side surface in the coil shape correcting step can be advanced and retracted with respect to the resin injection space in the mold. Therefore, the coil pressing means can be retracted from the resin injection space after the coil side surface is pressed by the coil pressing means. Can be injected.

  According to the method for manufacturing a molded coil of the present invention, the space factor and the heat dissipation property are not lowered by pressing the coil arranged in the mold and resin-molding the surface of the coil after correcting the shape. And it can be set as the manufacturing method of a mold coil with sufficient manufacture efficiency.

  With reference to the following drawings, a method for manufacturing a molded coil according to an embodiment of the present invention will be described for the understanding of the present invention. However, the following description is an embodiment of the present invention, and does not limit the contents described in the claims.

  FIG. 1 is an overall perspective view of a molded coil manufactured by a method for manufacturing a molded coil according to an embodiment of the present invention. FIG. 2 is a diagram showing a coil placement process according to the embodiment of the present invention, and shows a state in which the coil is placed in a mold. FIG. 3 is a diagram showing a coil placement process according to the embodiment of the present invention, and shows a state where the coil and the lower mold are fitted together. FIGS. 4A and 4B are plan views showing the coil shape correction step, where FIG. 4A shows a state before the coil shape correction, and FIG. 4B shows a state after the coil shape correction. FIG. 5 is a view showing a modification of the coil pressing means. 6A and 6B are plan views showing a coil shape correcting step using the coil pressing means shown in FIG. 5, wherein FIG. 6A shows a state before the coil shape correction, and FIG. 6B shows a state after the coil shape correction.

  First, with reference to FIGS. 1-4, the manufacturing method of the mold coil which concerns on embodiment of this invention is demonstrated.

  Referring to FIG. 1, a molded coil 1 according to an embodiment of the present invention is a coil in which the surface of a coil is resin-molded, and includes a coil 10 and a resin 20. The molded coil 1 is fitted with the divided stator core 30 of the motor shown in FIG. 1 to constitute a divided stator. Of course, the core is not necessarily limited to the divided stator core of the motor, and may be any core such as a transformer constituting a transformer or a reactor.

  As shown in FIG. 2, the coil 10 is a flat wire edgewise winding coil. Although not shown in detail in FIG. 2, the rectangular wire constituting the coil 10 is in close contact with the coil axis direction. With such a configuration, there is no gap between adjacent rectangular wires. Therefore, the heat conduction between the rectangular wires can be improved. Therefore, the heat dissipation of the molded coil 1 can be improved.

  The rectangular wire constituting the coil 10 may be any wire as long as it is normally used as a wire such as copper, aluminum, silver, gold, and alloys thereof. Further, the flat wire may be either an assembly line composed of a plurality of strands, or a strand composed of a single strand. Further, it is not necessarily a flat wire, and the shape, material, conductive diameter and the like can be appropriately changed as long as it is normally used as a wire constituting a coil such as a round wire, a hexagonal wire, and a rectangular wire.

The resin 20 is for molding the surface of the coil 10.
As shown in FIG. 1, the surface of the coil 10 excluding the rotor side end face 10 a is molded with a resin 20. By setting it as such a structure, a clearance gap does not arise between the coil surface except the rotor side end surface 10a, and the resin 20. FIG. Therefore, the heat generated in the coil 10 is quickly conducted to the outside through the resin 20 that is in close contact with the coil 10 without passing through an air layer, and is radiated. Therefore, the heat dissipation of the mold coil 1 can be improved.

  Further, as shown in FIG. 1, when the coil side surface 10b is resin-molded, when the molded coil 1 is fitted with a plurality of divided stator cores 30 arranged in a ring shape, insulation between adjacent coils 10 is achieved. Can be reliably performed, and insulation from the divided stator core 30 can be reliably performed. Further, by using the rotor-side end face 10a that does not come into contact with the core 10 and does not need to be resin-molded as a coil exposed portion, the amount of resin 20 used can be suppressed, and the cost-considered molded coil 1 is obtained. be able to. Of course, the coil 10 molded with the resin 20 is protected from external damage.

  The thickness of the resin 20 that molds the surface of the coil 10 needs to satisfy the insulation against the line voltage according to the applied voltage and the connection method, and at least 0.15 mm or more in consideration of the space factor and heat dissipation. It is desirable that

The resin 20 may be any resin as long as it is normally used as a mold resin, such as a thermosetting resin such as an epoxy resin or a thermoplastic resin.
In the present embodiment, the rotor side end face 10a is not molded with the resin 20. However, of course, the rotor side end face 10a may be molded with the resin 20.

Next, with reference to FIGS. 2-4, the manufacturing method of the mold coil 1 which concerns on embodiment of this invention is demonstrated.
The molded coil 1 according to the embodiment of the present invention is a coil whose surface is resin-molded. The mold coil 1 is manufactured by arranging the coil 10 in a simplified mold 100 and injecting the resin 20 into the mold after correcting the coil shape.
Here, as shown in FIG. 2, the mold 100 includes a lower mold 110 and an upper mold 120. As shown in FIG. 2, the lower mold 110 includes a fitting recess 111 for fitting the coil 10, a core mold 112 at the center of the fitting recess 111, and a coil pressing means 113 for correcting the coil shape.

First, the coil placement process will be described with reference to FIGS.
The coil placement process is a process of placing the coil 10 in the mold 100. Specifically, this is a step of fitting the coil 10 and the lower mold 110 together.

First, as shown in FIG. 2, the coil 10 that is in close contact in the axial direction is placed in the mold 100.
Then, the fitting recess 111 and the core mold 112 are positioned while the coil 10 is gripped by the gripping means and positioning means (not shown), and the coil 10 and the lower mold 110 are fitted together as shown in FIG. . As a result, as shown in FIG. 3, resin injection spaces L and M are formed in the fitting recess 111.

Next, the coil shape correction process will be described with reference to FIGS.
The coil shape correcting step is a step of correcting the shape of the coil side and the side surface of the coil end of the coil 10 arranged on the lower mold 110 by pressing the coil pressing means 113.
That is, as shown in FIG. 4A, the shapes of the coil side and the coil end side surfaces 10b and 10c of the coil 10 wound in an edgewise manner are usually flat due to a cause such as a deviation between rectangular wires. It does not become and has unevenness. Therefore, the space factor is reduced as compared with the case where the resin 20 is molded in a flush state, the heat dissipation is also poor, and further, the amount of resin used is increased, resulting in the disadvantage of poor production efficiency. Therefore, the above-mentioned demerits can be eliminated by correcting the shapes of the coil side and coil end side surfaces 10b and 10c to the same shape by the coil shape correcting step.

Specifically, as shown in FIG. 3, in a state where the coil 10 and the lower mold 110 are fitted together, the coil pressing means 113 is moved into the resin injection space L as shown by a black arrow in FIG. And squeeze out.
Here, the coil pressing means 113 has a cubic shape as shown in FIG. 2, and normally only the end surface 113 a of the lower mold 110 is configured with a part of each of the four side surfaces 111 a in the fitting recess 111. Arranged inside. Although not shown in detail, the coil pressing means 113 includes a mechanism that can move forward and backward with respect to the resin injection space L, as indicated by a black arrow in FIG.

Then, as shown in FIG. 4B, the coil pressing means 113 presses the coil side and coil end side surfaces 10b and 10c from the outside.
Here, since the coil pressing means 113 has a cubic shape, the contact portions of the coil side and the coil end side surfaces 10b and 10c can be in surface contact, and the coil side and coil end side surfaces 10b and 10c are configured. The conducting wire to be pressed can be integrally pressed with the surface. Further, as shown in FIG. 4, the coil pressing means 113 is arranged on the outer four sides of the coil side and coil end side surfaces 10b and 10c, respectively. Can be pressed. Therefore, the side surfaces 10b and 10c of the coil side and the coil end can be corrected to the same shape. Accordingly, it is possible to prevent a decrease in space factor, a deterioration in heat dissipation, and a decrease in manufacturing efficiency.

  And as shown in FIG.4 (b), the resin injection | pouring process is started in the state which the coil press means 113 pressed the coil side and the side surfaces 10b and 10c of the coil end from the outer four sides.

Next, the resin injection process will be described with reference to FIG.
The resin injection process is a process for molding the surface of the coil 10 by injecting the resin 20 into the mold 100.

First, as shown in FIG. 4B, the coil 20 and the coil end side surfaces 10b and 10c are pressed from the outer four sides to be flush with the resin 20 from the resin injection path (not shown). It is injected into the resin injection spaces L and M. Then, after the shape of the coil side and the coil end side surfaces 10 b and 10 c that are flush with each other is fixed by the resin 20, the coil pressing means 113 is moved to its original position, that is, only the end surface 113 a is in the fitting recess 111. The four side surfaces 111a are retracted to positions constituting a part thereof. Thereafter, the resin 20 is further injected into the resin injection space L. By setting it as such a structure, the part which the coil press means 113 protruded in the resin injection | pouring space L is resin-molded.
The molded coil 1 shown in FIG. 1 is shape | molded through the above process.

  The shape and number of the coil pressing means 113, the pressing positions of the coil sides and the coil end side surfaces 10b and 10c do not have to be limited to those of the present embodiment, and can be changed as appropriate. It is desirable that the side surfaces 10b and 10c can be pressed together in surface contact with the conductors constituting the side surfaces 10b and 10c.

Next, a modified example of the coil pressing means and a coil shape correcting step using the modified example will be described with reference to FIGS.
As shown in FIGS. 5 and 6, the coil pressing means 114 is configured such that the coil pressing means 113 described above presses the side surfaces 10 b and 10 c of the coil side and the coil end from the outside. The end side surfaces 10b and 10c are pressed from the inside.
The same functions and the same members as those in the coil shape correcting step using the coil pressing means 113 described above are denoted by the same reference numerals, and the following description is omitted.

As shown in FIG. 6, the coil pressing means 114 having a cubic shape that constitutes a part of each of the four side surfaces 112 a of the core mold 112 in a state where the coil 10 and the core mold 112 are fitted together is provided in the resin injection space M. And squeeze out.
Although not shown in detail in FIGS. 5 and 6, the coil pressing means 114 includes a mechanism that can move forward and backward with respect to the resin injection space M.
Then, the coil pressing means 114 presses the coil side and coil end side surfaces 10b and 10c from the inside.

  Here, since the coil pressing means 114 has a cubic shape, the contact portions with the coil side and the coil end side surfaces 10b and 10c can be in surface contact, and the coil side and coil end side surfaces 10b and 10c are configured. The conducting wire to be pressed can be integrally pressed with the surface. Further, as shown in FIG. 5, the coil pressing means 114 is arranged on each of the four inner sides of the coil side and coil end side surfaces 10b and 10c, so that the coil side and coil end side surfaces 10b and 10c are simultaneously attached. Can be pressed. Therefore, the side surfaces 10b and 10c of the coil side and the coil end can be corrected to the same shape. Accordingly, it is possible to prevent a decrease in space factor, a deterioration in heat dissipation, and a decrease in manufacturing efficiency.

  In the present embodiment, the coil 10 is pressed using the coil pressing means from either the outer side or the inner side of the coil side and coil end side surfaces 10b and 10c. However, the present invention is not limited to this configuration. Instead, the coil 10 may be configured to be pressed from both the outer side and the inner side of the coil side and the coil end side surfaces 10b and 10c using the coil pressing means. The four coil pressing means constituting the coil pressing means 113, 114 are configured to press the coil side and the coil end side surfaces 10b, 10c simultaneously, but may be configured to press each separately.

  In addition, after the shapes of the coil side and the coil end side surfaces 10 b and 10 c that are flush with each other are fixed by the resin 20, the coil pressing means 113 is placed in the original position, that is, only the end surface 113 a is in the fitting recess 111. Although it is set as the structure made to retreat to the position which comprises each part of the four side surfaces 111a, it does not necessarily need to be restricted to such a structure. For example, in the resin injection process, the coil pressing means 113 that presses the side surface 10c of the coil end can be configured to remain pressed without being retracted. By setting it as such a structure, a recessed part can be formed in the resin surface given to the side surface 10c of a coil end. Therefore, when the stator is configured by fitting the mold coil 1 into the ring-shaped stator core, the recess can be used as a groove for fitting the ring-shaped bus bar folder, and the connection between the stator 1 and the bus bar is easy. Can be.

  INDUSTRIAL APPLICABILITY The present invention can be used for various motors such as motors, transformers, reactors, and generators as molded coils and stators using the molded coils.

It is the whole mold coil perspective view manufactured with the manufacturing method of the mold coil concerning the embodiment of the present invention. It is a figure which shows the coil arrangement | positioning process which concerns on embodiment of this invention, and shows the state which arrange | positions a coil to a metal mold | die. It is a figure which shows the coil arrangement | positioning process which concerns on embodiment of this invention, and shows the state which fitted the coil and the lower mold | type. It is a top view which shows a coil shape correction process, (a) shows the state before coil shape correction, (b) shows the state after coil shape correction. It is a figure which shows the modification of a coil press means. It is a top view which shows the coil shape correction process using the coil press means shown in FIG. 5, (a) shows the state before coil shape correction, (b) shows the state after coil shape correction.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Mold coil 10 Coil 10a Rotor side end surface 10b Side surface 10c Side surface 20 Resin 30 Split stator core 100 Mold 110 Lower mold 111 Fitting recessed part 111a Fitting recessed part side surface 112 Core mold 112a Side surface 113 Coil pressing means 113a End surface 114 Coil pressing means 120 On Mold L Resin injection space M Resin injection space

Claims (2)

  A method of manufacturing a molded coil in which the surface of a coil is resin-molded by injecting a resin into a mold in which the coil is arranged, and at least a coil arranging step for arranging the coil in a mold, and a mold A coil shape correcting step of correcting the coil shape by pressing the coil side surface from either the inside or the outside of the arranged coil, and a resin injecting step of injecting resin to the surface of the coil arranged in the mold A method for producing a molded coil, comprising:   2. The method of manufacturing a molded coil according to claim 1, wherein the pressing of the coil side surface in the coil shape correcting step is performed by a coil pressing means having a mechanism capable of moving forward and backward with respect to the resin injection space in the mold. .

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