JP2010021506A - Method of manufacturing molded coil and molded coil - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a molded coil for reliably and easily securing resin with fixed thicknesses on an outside peripheral surface and an inside peripheral surface of a coil; and to provide a molded coil obtained by reliably applying the resin with the fixed thicknesses to the outside peripheral surface and the inside peripheral surface of the coil. <P>SOLUTION: The coil 10 is arranged in an annular coil arrangement space 51 constituted between an inward facing wall surface 52 and an outward facing wall surface 53 in a metal mold 50, so that a coil outside gap 51a is formed between the outside peripheral surface of the coil 10 and the inward facing wall surface 52 and a coil inside gap 51b is formed between the inside peripheral surface of the coil 10 and the outward facing wall surface 53. A spacer 60 is inserted into part of either one or both of the coil outside gap 51a and the coil inside gap 51b to hold the coil outside gap 51a and the coil inside gap 51b at respective fixed gap thicknesses. Consequently, a molded coil securing resin coats with respective fixed thicknesses on the outside peripheral surface and the inside peripheral surface of the coil 10 can be obtained. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a molded coil and a molded coil.

For example, when the coil is pre-molded with a resin or the like and combined with the core as a motor component, for example, the coil can be easily combined and the insulating property can be maintained, so that there is an advantage that the handling is easy.
On the other hand, there is a problem that it is difficult to accurately ensure the thickness of the resin applied to the inner peripheral surface and the outer peripheral surface of the coil.
As a method for producing a molded coil, for example, an invention according to Japanese Patent Application Laid-Open No. 57-93515 (Patent Document 1 below) has been disclosed. The invention of Patent Document 1 is intended to ensure the insulation between the upper and lower portions of each partial coil (10) stacked in a plurality of stages. For this reason, the insulating spacer (11) is fixed to the inner and outer peripheral surfaces of the partial coils (10), and the respective insulating spacers (11) are fixed to the inner mold (12c) and the outer mold (12d). A gap is secured between the upper and lower sides of the coil (10). Thus, the upper and lower portions of the partial coils (10) are formed as insulating layers filled only with the mold resin.
In addition, the invention according to Japanese Patent Laid-Open No. 7-14725 (Patent Document 2 below) is intended to provide a molded coil that is easy to manufacture and excellent in insulation performance. Is composed of a sheet-like insulating material (1), a first thin-leaf-like insulating material layer (2), a solid insulating material layer (3), and a second thin-leaf-like insulating material layer (4). And a manufacturing method thereof.
Further, in the invention according to Japanese Patent Laid-Open No. 11-3824 (Patent Document 3 below), a spacer (in order to make the coil (3) placed in the mold (2) float from the lower surface of the mold (2). 11), and a configuration in which a tapered pleat (12) is provided in the shape of the spacer (11) is disclosed. As a result, the contact surface between the coil (3) and the spacer (11) becomes small, and the resin enters well.
Japanese Utility Model Publication No. 57-93515 Japanese Patent Laid-Open No. 7-14725 Japanese Patent Laid-Open No. 11-3824

The manufacturing method of the mold coil disclosed in the above-mentioned Patent Document 1 is a manufacturing method that aims to secure an insulating layer with a molding resin between the upper and lower partial coils (10) and is achieved. However, this is not a manufacturing method for ensuring a constant thickness of the resin injected around the coil (10). The insulating spacer (11) shown in Patent Document 1 is first fixed to the coil (10) and further needs to be coupled to the inner mold (12c) and the outer mold (12d). It is different from a spacer having the property that it can be easily inserted into the space later. This requires a lot of work and requires time and accuracy.
That is, the method of manufacturing a molded coil using the insulating spacer (11) disclosed in Patent Document 1 is intended to insulate the upper and lower parts of the partial coil (10), and it takes time to handle the insulating spacer (11). It takes time.
Further, the molded coil and the manufacturing method thereof disclosed in Patent Document 2 are aimed at obtaining a molded coil with good insulation performance by applying a plurality of insulating material layers (1) to (4) inside the molded coil. And achieved. However, it is not intended to secure a resin layer having a certain thickness on the outer peripheral surface or inner peripheral surface of the coil, and does not disclose means for achieving such an object.
Further, the molded coil disclosed in Patent Document 3 uses a spacer (11) in order to make the coil (3) placed in the mold (2) float from the lower surface of the mold (2). There are things. On the other hand, it is not intended to secure a certain thickness of resin layer on the outer peripheral surface or inner peripheral surface of the coil, nor is it disclosed a means for achieving such an object.

  Accordingly, the present invention provides a method for producing a molded coil that can reliably and easily ensure a certain thickness of resin on the outer peripheral surface and the inner peripheral surface of the coil, based on an object and viewpoint different from the above-described prior art. Is an issue. Another object of the present invention is to provide a molded coil in which a certain thickness of resin is reliably applied to the outer peripheral surface and the inner peripheral surface of the coil.

  The method for manufacturing a molded coil according to the present invention is a method for manufacturing a molded coil in which a coil is disposed in a mold and a resin having a certain thickness is applied to the outer peripheral surface of the coil and the inner peripheral surface of the coil. The coil is disposed in an annular coil arrangement space formed between the inward wall surface and the outward wall surface in the mold, thereby providing a coil outer gap between the outer peripheral surface of the coil and the inward wall surface. In addition, a coil inner gap is formed between the inner peripheral surface of the coil and the outward wall surface, and a spacer is inserted into a part of one or both of the coil outer gap and the coil inner gap. The coil outer gap and the coil inner gap are each maintained at a constant gap thickness, thereby ensuring a resin coating with a constant thickness on the outer peripheral surface and the inner peripheral surface of the coil, respectively. Toi .

According to the first feature of the present invention, the spacer is inserted into the coil outer gap or the coil inner gap when the coil is arranged in the coil arrangement space in the mold, so that the gap into which the spacer is inserted is inserted. The dimension can be secured with the thickness of the spacer. Of course, the gap in which the spacer is not inserted is inevitably determined by determining the size of the gap in which the spacer is inserted.
That is, for example, by inserting a spacer in the coil inner gap, the thickness of the resin coating applied to the inner peripheral surface of the coil can be ensured to be the same constant as the thickness of the spacer. When the dimension of the coil inner gap is determined by the spacer, the dimension of the coil outer gap where the spacer is not inserted is also determined.
Similarly, by inserting a spacer into the coil outer gap, it is possible to ensure that the thickness of the resin coating applied to the outer peripheral surface of the coil is the same constant thickness as the spacer. When the dimension of the coil outer gap is determined by the insertion of the spacer, the dimension of the coil inner gap in which the spacer is not inserted is also determined.
Also, spacers can be inserted into both the coil inner gap and the outer gap. Also in this case, the dimensions of the coil inner gap and the coil outer gap are determined, and it is possible to ensure a constant thickness of the resin coating applied to the coil inner circumferential surface and the coil outer circumferential surface.

  In addition to the first feature of the present invention described above, the method for manufacturing a molded coil according to the present invention includes a part on the coil side and a part on the coil end side in one or both of the coil outer gap and the coil inner gap. The second feature is that a spacer is inserted into the portion.

According to the second feature of the present invention, in addition to the function and effect of the first feature, in the coil having the coil side and the coil end, the coil is placed in the coil placement space in the mold. By inserting a spacer into a part on the coil side and a part on the coil end side in the coil outer gap and the coil inner gap, it is possible to secure the gap dimension in which the spacer is inserted with the thickness of the spacer. it can. Of course, the gap in which the spacer is not inserted is inevitably determined by determining the size of the gap in which the spacer is inserted.
That is, for example, when inserting a spacer into the coil inner gap of a coil having a coil side and a coil end such as a square or a rectangle, by inserting the spacer into a part on the coil side and a part on the coil end side, It becomes possible to ensure the thickness of the resin coating applied to the inner peripheral surface of the coil to the same constant thickness as the spacer. When the dimension of the coil inner gap is determined by the spacer, the dimension of the coil outer gap where the spacer is not inserted is also determined.
Similarly, when inserting a spacer into the coil outer gap of a coil having a coil side and a coil end such as a square or a rectangle, by inserting the spacer into a part on the coil side side and a part on the coil end side, It becomes possible to ensure the thickness of the resin coating applied to the outer peripheral surface of the coil to the same constant thickness as the spacer. When the dimension of the coil outer gap is determined by the insertion of the spacer, the dimension of the coil inner gap in which the spacer is not inserted is also determined.
Also, a spacer can be inserted into either the inner gap or the outer gap of a coil having a coil side such as a square or a rectangle and a coil end. Even in this case, by inserting spacers in a part on the coil side side and a part on the coil end side, the dimensions of the coil inner gap and the coil outer gap are determined, and the coil inner circumferential surface and the coil outer circumferential surface of the coil are determined. It is possible to ensure a constant thickness of the resin coating to be applied.

  In addition to the first feature of the present invention, the molded coil manufacturing method of the present invention corresponds to at least a pair of opposing corner portions of the coil in either one or both of the coil outer gap and the coil inner gap. The third feature is that a spacer is inserted.

According to the third feature of the present invention, in addition to the function and effect of the first feature, in the case of a coil having a plurality of pairs of corner portions, the coil is placed in the coil placement space in the mold. In addition, by inserting a spacer corresponding to at least a pair of opposing corner portions of the coil in the coil outer gap and the coil inner gap, it is possible to secure the gap dimension in which the spacer is inserted with the thickness of the spacer. it can. Of course, the gap in which the spacer is not inserted is inevitably determined by determining the size of the gap in which the spacer is inserted.
That is, for example, when inserting a spacer into a coil inner gap of a coil having a plurality of pairs of corners such as squares and rectangles, inserting the spacers corresponding to at least a pair of opposing corners of the coil It is possible to ensure the thickness of the resin coating applied to the inner peripheral surface to the same constant thickness as the spacer. When the dimension of the coil inner gap is determined by the spacer, the dimension of the coil outer gap where the spacer is not inserted is also determined.
The same applies to the case where a spacer is inserted into the coil outer gap of a coil having a plurality of pairs of corners such as a square or a rectangle.
In addition, a spacer may be inserted in either the coil inner gap or the outer gap of a coil having a plurality of pairs of corner portions such as a square or a rectangle. Also in this case, by inserting spacers corresponding to at least a pair of opposing corner portions of the coil, the dimensions of the coil inner gap and the coil outer gap are determined, and applied to the coil inner peripheral surface and the coil outer peripheral surface of the coil. It is possible to ensure a constant thickness of the resin coating.

  The molded coil manufacturing method of the present invention has a fourth feature that the coil shape is circular or elliptical in addition to the operational effects of the first feature.

  According to the fourth aspect of the present invention, in addition to the function and effect of the first aspect, the obtained molded coil has a circular or elliptical shape, so that the coil component such as a transformer or inductor having a cylindrical core can be obtained. Can also be preferably used.

  Moreover, in addition to any one of the first to fourth features of the present invention described above, the fifth feature of the molded coil manufacturing method of the present invention is that the coil is a flat edgewise coil.

  According to the fifth aspect of the present invention, in addition to the operational effect of any one of the first to fourth aspects of the present invention, a constant thickness is applied to the outer peripheral surface and the inner peripheral surface of the flat edgewise coil. It becomes possible to ensure and apply the resin. In particular, since a flat edgewise coil is often used as a square or rectangular coil, it can be used effectively when a resin is applied to such a flat edgewise coil.

  In addition to the first to fifth features of the present invention described above, the method for manufacturing a molded coil according to the present invention includes a spacer made of an insulating material of the same kind or different kind of resin, and the resin is injected with the resin by resin injection. The sixth feature is that they are integrated with each other.

According to the sixth aspect of the present invention, in addition to the function and effect of any one of the first to fifth aspects of the present invention, the spacer is made of an insulator and integrated with the coil together with the resin. This makes it possible to easily and easily manufacture a molded coil in which insulation is ensured in both thickness and material.
Further, by using the same type of spacer as the resin, it is possible to manufacture a molded coil having a uniform resin coating made of only the same type of resin. When the spacer is made of an insulator different from resin, it can be easily molded as a spacer, and a material suitable for insulation can be selected. Furthermore, a material having a linear expansion coefficient close to that of the spacer is more preferable because cracks and the like are hardly generated even in an environment where the temperature changes drastically.

  Moreover, in addition to any one of the first to sixth features of the present invention described above, the method for manufacturing a molded coil according to the present invention provides a plurality of coil arrangement spaces in a mold, and includes a plurality of coils as the plurality of coils. A seventh feature is that resin coating is applied to a plurality of coils at a time by arranging them in a coil arrangement space.

  According to the seventh feature of the present invention, in addition to the operational effect of any one of the first to sixth features of the present invention, a plurality of mold coils can be obtained at one time. Is easy to mass-produce.

  The eighth feature of the molded coil of the present invention is that it is manufactured by the method for manufacturing a molded coil according to any one of the first to seventh features.

  According to the eighth feature, in the molded coil manufactured by the manufacturing method of the first feature, a certain thickness of resin is reliably applied to the outer peripheral surface and the inner peripheral surface of the coil. can do. In the molded coil manufactured by the manufacturing method of the second feature, a resin having a certain thickness of resin is reliably applied to the outer peripheral surface and the inner peripheral surface of the coil having the coil side and the coil end. can do. Further, in the molded coil manufactured by the manufacturing method according to the third feature, there is provided a coil in which a certain thickness of resin is reliably applied to the outer peripheral surface and the inner peripheral surface of the coil having a plurality of pairs of corner portions. be able to. Further, in the molded coil manufactured by the manufacturing method according to the fourth feature, it is possible to provide a circular coil or an elliptical coil in which a certain thickness of resin is reliably applied to the outer peripheral surface and the inner peripheral surface. it can. In the molded coil manufactured by the manufacturing method according to the fifth feature, it is possible to provide a flat edgewise coil with a certain thickness of resin reliably applied to the outer peripheral surface and the inner peripheral surface. Further, in the molded coil manufactured by the manufacturing method according to the sixth feature, it is possible to provide a molded coil in which a spacer made of the same kind or different kind of insulator as that of the resin is integrated with the coating resin. Further, in the molded coil manufactured by the manufacturing method according to the seventh feature, it is possible to provide a mass-produced cost-competitive product.

According to the method for manufacturing a molded coil of the present invention, it is possible to easily and reliably manufacture a molded coil in which a certain thickness of resin is secured on the outer peripheral surface or inner peripheral surface of the coil.
Further, according to the molded coil of the present invention, it is possible to provide a molded coil in which a certain thickness of resin is reliably applied to the outer peripheral surface and the inner peripheral surface of the coil.

  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 a perspective view showing a method of manufacturing a molded coil according to an embodiment of the present invention and a coil before molding used in the molded coil, FIG. 2 is a perspective view showing the molded coil according to the embodiment, and FIG. The perspective view explaining arrangement | positioning of the metal mold | die, a coil, and a spacer in the manufacturing method which concerns on this embodiment, FIG. 4 is a top view explaining arrangement | positioning of the metal mold | die, coil, and spacer in the manufacturing method which concerns on 1st Embodiment. It is.

FIG. 1 shows the coil 10 before molding. The coil 10 includes a coil body 10a and a coil end portion 10b protruding from the coil body 10a. The coil end portion 10b is a portion corresponding to the start and end of winding of the coil.
The coil 10 has an outer peripheral surface 11, an inner peripheral surface 12, and both end surfaces 13, 13. When the coil 10 is used for a coil for a motor, other terminals are electrically connected to the coil end portion 10b. Will be.
The coil 10 shown in FIG. 1 is configured as a rectangular wire edgewise coil obtained by edgewise winding a single flat wire, and the one shown in the figure is rectangular.
One rectangular wire constituting the edgewise coil may be a composite of a plurality of parallel wires compressed and processed. By using an edgewise coil composed of a rectangular wire formed by combining a plurality of such wires, the performance as a winding used in a motor or the like can be improved.

FIG. 2 shows a molded coil 30 manufactured by the manufacturing method according to this embodiment. The molded coil 30 is obtained by integrating the resin 20 with the coil 10. In the present embodiment, the resin 20 is coated on the outer peripheral surface 11 of the coil 10 as the outer resin 21, and on the inner peripheral surface 12 as the inner resin 22, and not on the end surface 13 of the coil 10.
When the molded coil 30 is fitted into the core in order to make it a motor stator or other electromagnetic component, it is necessary to apply an inner resin 22 to at least the inner peripheral surface 12 of the coil 10 to ensure insulation from the core. . The outer peripheral surface 11 of the coil 10 may have a portion where the outer resin 21 is applied and a portion where the outer resin 21 is not applied. For example, the resin 21 may be applied to a portion that may come into contact with surrounding components, and the resin 21 may be left unapplied to a portion that is not likely to come into contact. The end face 13 of the coil 10 may be covered as well as not covered with the resin 20.
The coil end portion 10b protrudes out of the resin 20 and is exposed. Since the coil end portion 10b is often used for electrical connection, it must be exposed.

Referring to FIG. 3, the coil 10 shown in FIG. 1 is disposed in a mold 50, and resin 20 is injected to form a molded coil 30.
The mold 50 can be composed of a plurality of divided molds 50a, 50b, 50c. The divided molds 50a, 50b, and 50c are formed of three divided molds in the mold 50 shown in FIG. 3, but the coil body 10a of the coil 10 is disposed in the mold 50, and the coil end portion 10b. As long as the mold can be arranged in a state of being led out of the mold 50, any mold may be used, and the number of divisions is not limited.
In FIG. 3, the split molds 50 a and 50 b are already coupled, and the coil body 10 is disposed in the coil layout space 51 inside the mold, and the remaining split mold 50 c is not yet coupled. Indicates an open state.
In a state where the coil 10 is arranged in the coil arrangement space 51 of the mold 50, the coil end portion 10 b goes out of the mold 50.

The coil placement space 51 of the mold 50 is a space for placing the coil 10 therein and injecting the resin 20. An annular space is formed between the inward wall surface 52 and the outward wall surface 53 in the mold 50.
The width of the coil arrangement space 51, that is, the gap between the inward wall surface 52 and the outward wall surface 53 is larger than the width of the coil 10 (the width of the flat wire). Thus, by arranging the coil 10 in the coil arrangement space 51, a coil outer gap 51 a is formed between the outer peripheral surface 11 of the coil 10 and the inward wall surface 52 of the mold 50, and the inner peripheral surface of the coil 10. A coil inner gap 51 b is formed between the outer wall 12 and the outward wall surface 53 of the mold 50.
When the resin 20 is injected into the coil outer gap 51a, the outer resin 21 is formed on the outer peripheral surface 11 of the coil 10, and when the resin 20 is injected into the coil inner gap 51b, the inner resin 22 is formed. It is formed. Thereby, the molded coil 30 of FIG. 2 is formed.

When the coil 10 is arranged in the coil arrangement space 51 of the mold 50, the width (gap thickness) of the coil arrangement space 51 is usually larger than the width (thickness) of the coil 10. Therefore, if the coil 10 is simply disposed, the position of the coil 10 is likely to shift, and accurate positioning is difficult. That is, it is difficult to set the coil outer gap 51a and the coil inner gap 51b to a predetermined constant gap dimension (constant gap thickness).
On the other hand, for example, when the coil 10 is fitted into the core and used as an electromagnetic component, it may be necessary to ensure a certain withstand voltage with respect to the core. However, for this purpose, a resin layer having a certain thickness or more needs to be surely laminated on the entire inner peripheral surface 12 of the coil.
Therefore, in order to satisfy the above-described needs, it is necessary to ensure the coil inner gap 51b having a certain size in a state where the coil 10 is arranged in the coil arrangement space 51.

The coil outer gap 51a and the coil inner gap 51b are held at a constant gap size (gap thickness), respectively, whereby the outer resin 21 and the inner resin 22 having a predetermined thickness are respectively formed on the outer coil peripheral surface 11 and the inner coil surface 12. In order to ensure the coating of the resin 20 by the spacer 60 is used in the present invention.
One or more spacers 60 can be inserted into the coil outer gap 51a. In this case, at least the dimension (thickness) of the coil outer gap 51a can be at least equal to or greater than the thickness of the spacer 60. That is, the thickness of the outer resin 21 applied to the coil outer peripheral surface 11 can be ensured to be equal to or greater than the thickness of the spacer 60.
One or more spacers 60 can be inserted into the coil inner gap 51b. In this case, at least the dimension (thickness) of the coil inner gap 51b can be at least equal to or greater than the thickness of the spacer 60. That is, the thickness of the inner resin 22 applied to the coil inner peripheral surface 12 can be ensured to be equal to or greater than the thickness of the spacer 60.
A plurality of spacers 60 can be inserted into both the coil outer gap 51a and the coil inner gap 51b. In this case, the dimension (thickness) of the coil outer gap 51a and the dimension (thickness) of the coil inner gap 51b can be equal to or greater than the thickness of the spacer 60 to be inserted. That is, both the thickness of the outer resin 21 applied to the coil outer peripheral surface 11 and the thickness of the inner resin 22 applied to the coil inner peripheral surface 12 can be ensured to be equal to or greater than the thickness of the spacer 60 to be inserted.
Of course, when the gap dimension (gap thickness) of the coil arrangement space 51 is formed equal to the sum of the width of the coil 10 (width of the flat wire), the thickness of the outer resin 21 to be covered, and the thickness of the inner resin 22, By inserting the spacer 60 into the coil outer gap 51a, the thickness of the outer resin 21 applied to the coil outer peripheral surface 11 can be set to a desired constant thickness, and the inner resin applied to the coil inner peripheral surface 12 The thickness of 22 can be set to a desired constant thickness. Similarly, by inserting the spacer 60 into the coil inner gap 51b, the thickness of the inner resin 22 applied to the coil inner peripheral surface 12 can be set to a desired constant thickness, and it is applied to the coil outer peripheral surface 11. The thickness of the outer resin 21 can also be set to a desired constant thickness.

The material of the resin 20 applied to the coil 10 is not particularly limited. However, various types of resins having excellent insulating properties can be selected and used according to the insulating conditions required for the mold coil 30. For example, an epoxy resin, a phenol resin, or an unsaturated polyester resin can be used.
The material of the spacer 60 is not particularly limited, but various kinds of resins having excellent insulating properties can be selected and used according to the insulating conditions required for the molded coil 30. When the resin 20 and the spacer 60 are integrated to form a coating layer, the spacer 60 is preferably made of the same material as the resin 20. Of course, different materials can be used.

With reference to FIG. 3 and FIG. 4, an example of inserting the spacer 60 when the coil 10 is a flat edgewise coil will be described.
In the case shown in FIGS. 3 and 4, the spacer 60 is a flat spacer 61, which is inserted into the coil side gap 51b and the coil end side, respectively. In the case of an edgewise coil, it is to be applied to the inner peripheral surface 12 of the coil 10 by inserting a total of two flat spacers 61 at least on the coil side side and the coil end side into the coil inner gap 51b. The thickness of the inner resin 22 can be ensured to a predetermined constant thickness (the thickness of the flat spacer 61). Of course, a larger number of plate-like spacers 61 may be inserted into the coil inner gap 51b or in addition to the coil outer gap 51a. By inserting the spacer 61 into the coil outer gap 51a, the thickness of the outer resin 21 of the coil 10 can be ensured to be constant.
The flat spacer 61 to be inserted on the coil side side has a size that can be inserted into a part of the coil inner side gap 51b on the coil side side, not the whole. Similarly, the flat spacer 61 inserted on the coil end side has a size that can be inserted into a part of the coil inner gap 51b on the coil end side instead of the whole. In this way, the resin 20 is actually injected into the coil inner gap 51 b and the coil inner peripheral surface 12 can be covered with the inner resin 22.
In the above case, when the resin 20 is injected while the flat spacer 61 is inserted, the flat spacer 61 and the resin 20 are integrated to form a coating layer.

When the coil 10 is arranged in the coil arrangement space 51 of the mold 50 and the spacer 61 is inserted and the position of the coil 10 is positioned at a predetermined position, the remaining divided mold 50c is coupled to the divided mold 50b. Thereby, the setting of the coil 10 to the mold 50 is completed. The resin 20 is injected into the mold 50 from an injection port (not shown), and the gap between the mold 50 and the coil 10 is filled. After the resin 20 has hardened, the mold coil 30 can be obtained by disassembling and removing the mold 50.
The obtained molded coil 30 has an inner resin 22 layer having a certain thickness secured on the inner peripheral surface 12 of the coil 10. Further, the flat spacer 61 forms a coating layer integrally with the inner resin 22. When the flat spacer 61 is the same insulating resin as the inner resin 22, the entire inner resin 22 layer of the coil 10 becomes a single resin layer made of a single insulating resin.

A second embodiment of the present invention will be described with reference to FIG. FIG. 5 is a plan view for explaining the arrangement of a mold, a coil, and a spacer in the manufacturing method according to the second embodiment.
In the second embodiment, the spacer 60 is a U-shaped spacer 62, and the U-shaped spacer 62 extends from the coil side to the adjacent coil end side in the coil inner gap 51 b of the coil arrangement space 51. I try to insert it. The cross-sectional thickness of the U-shaped spacer 62 is the same as the thickness of the inner resin 22 to be coated on the inner peripheral surface 12 of the coil 10. On the other hand, it is preferable that the height dimension of the cross-sectionally U-shaped spacer 62 be lower than the height of the coil 10 arranged in the coil arrangement space 51 in order to integrate with the injected resin.
By inserting the cross-sectionally U-shaped spacer 62 into the coil inner gap 51b, the thickness of the inner resin 22 of the coil 10 can be secured to a predetermined constant thickness. Of course, by inserting the U-shaped spacer 62 in the coil outer gap 51a, the thickness of the outer resin 21 of the coil 10 can also be secured to a predetermined constant thickness.
The construction of the cross-sectionally U-shaped spacer 62 with an insulating material, and further with the same insulating resin as the resin 20 is the same as in the case of the flat spacer 61.
The obtained molded coil 30 has an inner resin 22 layer having a certain thickness secured on the inner peripheral surface 12 of the coil 10. Further, the U-shaped spacer 62 is formed integrally with the inner resin 22 to form a coating layer. When the U-shaped spacer 62 is the same insulating resin as the inner resin 22, the entire inner resin 22 layer of the coil 10 is a single resin layer made of a single insulating resin.

A third embodiment of the present invention will be described with reference to FIG. FIG. 6 is a plan view for explaining the arrangement of a mold, a coil, and a spacer in the manufacturing method according to the third embodiment.
In the third embodiment, the spacer 60 is a corner arrangement spacer 63 and is inserted into the corner portion of the flat edge-wise coil 10. That is, the corner placement spacer 63 is inserted across the both sides of the coil side side and the coil end side in the coil inner space 51 b of the coil placement space 51. The cross-sectional thickness of the corner arrangement spacer 63 is the same as the thickness of the inner resin 22 to be coated on the inner peripheral surface 12 of the coil 10.
By inserting the corner arrangement spacer 63 into two opposing corner portions in the coil inner gap 51b, the thickness of the inner resin 22 of the coil 10 can be secured to a predetermined constant thickness. Of course, by inserting the corner arrangement spacer 63 into the coil outer gap 51a, the thickness of the outer resin 21 of the coil 10 can also be secured to a predetermined constant thickness.
The corner arrangement spacer 63 is made of an insulating material, and further, the corner arrangement spacer 63 is made of the same insulating resin as the resin 20 as in the case of the flat spacer 61 and the U-shaped spacer 62.
The obtained molded coil 30 has an inner resin 22 layer having a certain thickness secured on the inner peripheral surface 12 of the coil 10. Further, the corner arrangement spacer 63 is formed integrally with the inner resin 22 to form a coating layer. When the corner placement spacer 63 is the same insulating resin as the inner resin 22, the entire inner resin 22 layer of the coil 10 becomes a single resin layer made of a single insulating resin.

A fourth embodiment of the present invention will be described with reference to FIG. FIG. 7 is a plan view for explaining an arrangement of a mold, a coil, and a spacer in the manufacturing method according to the fourth embodiment.
In the fourth embodiment, a configuration is adopted in which the spacer 60 is a columnar spacer 64 and is appropriately inserted into the coil side side, the coil end side, and further the corner portion in the coil inner gap 51b of the coil arrangement space 51. . By making the diameter of the circle of the columnar spacer 64 the same as the predetermined thickness of the inner resin 22 to be coated on the inner peripheral surface 12 of the coil 10, the inner resin 22 layer having a predetermined thickness can be secured.
The cylindrical spacer 64 is appropriately inserted into the coil side side, the coil end side, and the corner portion of the coil outer gap 51a, whereby the thickness of the outer resin 21 of the coil 10 can be ensured to a predetermined constant thickness.
The cylindrical spacer 64 is made of an insulating material, and further, the cylindrical spacer 64 is made of the same insulating resin as the resin 20, as in the case of the flat plate spacer 61, the cross-sectionally U-shaped spacer 62, and the corner arrangement spacer 63. is there.
The obtained molded coil 30 has an inner resin 22 layer having a certain thickness secured on the inner peripheral surface 12 of the coil 10. Further, the cylindrical spacer 64 forms a coating layer integrally with the inner resin 22. When the columnar spacer 63 is the same insulating resin as the inner resin 22, the entire inner resin 22 layer of the coil 10 becomes a single resin layer made of a single insulating resin.

In addition, the spacer 60 can be used in combination with the above-mentioned flat spacer 61, cross-sectional spacer 62, corner arrangement spacer 63, cylindrical spacer 64, and the like.
Further, by inserting the spacer 60 into both the coil inner gap 51b and the outer gap 51a, the coil 10 can be completely positioned. When the spacer 60 is inserted into only one of the coil inner gap 51b and the outer gap 51a, the dimension of the gap (51b or 51a) on which the spacer 60 is inserted is secured, and the corresponding coil inner peripheral surface (12). Or it becomes possible to ensure the thickness of inner resin (22) or outer resin (21) given to coil outer peripheral surface (11) to predetermined thickness.
Further, even when the shape of the coil 10 is slightly incomplete due to the use of the spacer 60, the shape of the coil 10 is corrected by inserting the spacer 60 into the coil inner gap 51b or the coil outer gap 51a. The resin 20 can be injected in the corrected state.

  In the above-described embodiment, an example using a flat edgewise coil has been described. However, the coil 10 to be used is not necessarily a flat edgewise coil. A flat wire, a round wire, and other cross-sectional lines that are circular coils or elliptic coils can be used. By obtaining such a molded coil using a circular coil or an elliptical coil, the core can be used as a cylindrical coil component.

With reference to FIG. 8, a fifth embodiment of the present invention using a circular coil will be described. FIG. 8 is a plan view for explaining the arrangement of a mold, a coil, and a spacer in the manufacturing method according to the fifth embodiment.
In the fifth embodiment, an example in which a circular coil 70 is used as a coil is shown. As for the wire constituting the circular coil 70, a round wire or a wire having another cross section can be used in addition to a flat wire.
The circular coil 70 is resin-molded by placing the coil body 70a in the coil placement space 51 of the mold 50 (50b), as in the case of the above-described example. The coil end portion 70b of the circular coil 70 is led out of the coil placement space 51 so that the resin is not covered.
In this embodiment, the spacer 65 is inserted into the coil inner space 51 b in the coil arrangement space 51. A pair of spacers 65 are used, and are arranged in a state of facing each other at positions 180 degrees apart in the circumferential direction. The cross-sectional thickness of the spacer 65 is the same as the thickness of the inner resin 22 to be coated on the inner peripheral surface 72 of the circular coil 70.
By using at least a pair of spacers 65 and disposing them at opposing positions 180 degrees apart from each other in the circumferential direction of the coil inner gap 51b, the thickness of the inner resin 22 molded on the inner peripheral surface 72 of the coil 70 can be reduced. A predetermined constant thickness can be ensured. Three or more spacers 65 may be used.
Of course, the pair of spacers 65 and 65 are inserted into the outer circumferential surface 71 of the coil 70 by inserting them into the outer coil gap 51a at positions opposed to each other by 180 degrees in the circumferential direction instead of or together with the inner coil gap 51b. The outer resin 21 is molded so that the thickness of the outer resin 21 can be kept constant.
In the case of the flat spacer 61, the cross-sectional spacer 62, the corner arrangement spacer 63, and the cylindrical spacer 64, the spacer 65 is made of an insulating material, and further, is made of the same insulating resin as the resin 20. It is the same.
The obtained molded coil 30 has an inner resin 22 layer with a certain thickness secured on the inner peripheral surface 72 of the circular coil 70. Further, the spacer 65 forms a coating layer integrally with the inner resin 22. When the spacer 65 is the same insulating resin as the inner resin 22, the entire inner resin 22 layer of the circular coil 70 becomes a single resin layer made of a single insulating resin.
The shape of the spacer 65 is not particularly limited, and may be any shape that can position the circular coil 70, such as an arc shape, a cylindrical shape, a rectangular parallelepiped shape, or the like along the shape of the circular coil 70.

With reference to FIG. 9, a sixth embodiment of the present invention using an elliptical coil will be described. FIG. 9 is a plan view for explaining the arrangement of a mold, a coil, and a spacer in the manufacturing method according to the sixth embodiment.
In the sixth embodiment, an example in which an elliptical coil 80 is used as a coil is shown. As for the wire constituting the elliptical coil 80, a flat wire, a round wire, or a wire having another cross section can be used.
The elliptical coil 80 is resin-molded by placing the coil body 80a in the coil placement space 51 of the mold 50 (50b), as in the above-described example. The coil end portion 80b of the elliptical coil 80 is led out of the coil placement space 51 so that the resin is not covered.
The usage, material, and others of the spacer 66 are the same as those of the spacer 65 described above.
The obtained molded coil 30 has an inner resin 22 layer having a certain thickness secured on the inner peripheral surface 82 of the elliptical coil 80. Further, the spacer 66 integrally forms a coating layer with the inner resin 22. When the spacer 66 is the same insulating resin as the inner resin 22, the entire inner resin 22 layer of the elliptical coil 80 becomes a single resin layer made of a single insulating resin.
The shape of the spacer 66 is not particularly limited, and may be any shape that can position the elliptical coil 80 such as an arc shape, a cylindrical shape, a rectangular parallelepiped shape, or the like along the shape of the elliptical coil 80.

A seventh embodiment of the present invention will be described with reference to FIG. FIG. 10 is a plan view for explaining the mold, the coil arrangement space, and the coil arrangement in the manufacturing method according to the seventh embodiment.
In the seventh embodiment, a plurality of coil arrangement spaces 51 are formed in the mold 50 (50a, 50b, 50c). By using such a mold 50, a plurality of coils can be manufactured at a time by arranging a plurality of coils in a plurality of coil arrangement spaces 51 of the mold 50 and molding the resin 20. .
In FIG. 10, the circular coil 70 is shown, and the spacer 65 and the coil arrangement space 51 are shown for the circular coil 70, but the coil to be used is not limited to the circular coil 70, but a rectangular edge. A Wise coil 10, an elliptical coil 80, and other shaped coils can be used. That is, a die in which a coil arrangement space 51 having a corresponding shape is formed by using corresponding spacers 61 to 64 and 66 according to a coil 10 having a rectangular edge width, an elliptical coil 80, and other coils. 50 may be used.

  The method for producing a molded coil and the molded coil of the present invention can be used in the fields of electric devices such as motors, transformers, and reactors, electromagnetic devices, and other industrial devices.

It is a perspective view which shows the coil before the mold used for the manufacturing method and the mold coil of the mold coil which concerns on embodiment of this invention. It is a perspective view which shows the mold coil which concerns on this embodiment. It is a perspective view explaining arrangement | positioning of the metal mold | die, a coil, and a spacer in the manufacturing method which concerns on 1st Embodiment. It is a top view explaining arrangement of a metallic mold, a coil, and a spacer in a manufacturing method concerning a 1st embodiment. It is a top view explaining arrangement of a metallic mold, a coil, and a spacer in a manufacturing method concerning a 2nd embodiment. It is a top view explaining arrangement of a metallic mold, a coil, and a spacer in a manufacturing method concerning a 3rd embodiment. It is a top view explaining arrangement | positioning of the metal mold | die, a coil, and a spacer in the manufacturing method which concerns on 4th Embodiment. It is a top view explaining arrangement | positioning of the metal mold | die, a coil, and a spacer with the manufacturing method which concerns on 5th Embodiment. It is a top view explaining arrangement of a metallic mold, a coil, and a spacer in a manufacturing method concerning a 6th embodiment. It is a top view explaining metal mold | die, coil arrangement | positioning space, and coil arrangement | positioning in the manufacturing method which concerns on 7th Embodiment.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Coil 10a Coil main body 10b Coil terminal part 11 Outer peripheral surface 12 Inner peripheral surface 13 End surface 20 Resin 21 Outer resin 22 Inner resin 30 Mold coil 50 Mold 50a Split mold 50b Split mold 50c Split mold 51 Coil arrangement space 51a Coil outer gap 51b Coil inner gap 52 Inward wall surface 53 Outward wall surface 60 Spacer 61 Flat spacer 62 Cross-section spacer 63 Corner spacer 64 Columnar spacer 65 Spacer 66 Spacer 70 Circular coil 70a Coil body 70b Coil end portion 71 Outer peripheral surface 72 Inner peripheral surface 80 Oval coil 80a Coil body 80b Coil end portion 81 Inner peripheral surface 82 Outer peripheral surface

Claims (8)

  A method of manufacturing a molded coil in which a coil is disposed in a mold and a constant thickness of resin is applied to the outer peripheral surface of the coil and the inner peripheral surface of the coil. Between the outer peripheral surface of the coil and the inward wall surface, and the outer peripheral surface of the coil and the outer peripheral surface of the coil. A coil inner gap is formed between the facing wall and a spacer is inserted into a part of one or both of the coil outer gap and the coil inner gap, thereby reducing the coil outer gap and the coil inner gap. A method for producing a molded coil, characterized in that a constant gap thickness is maintained, thereby ensuring a resin coating with a constant thickness on each of an outer peripheral surface and an inner peripheral surface of the coil.   The method for manufacturing a molded coil according to claim 1, wherein spacers are inserted into a part on the coil side side and a part on the coil end side in one or both of the coil outer gap and the coil inner gap.   2. The method for manufacturing a molded coil according to claim 1, wherein spacers are inserted in at least one of or both of the coil outer gap and the coil inner gap so as to correspond to a pair of opposing corner portions of the coil.   The method for manufacturing a molded coil according to claim 1, wherein the coil shape is circular or elliptical.   The method for manufacturing a molded coil according to claim 1, wherein the coil is a flat edgewise coil.   6. The mold coil manufacturing method according to claim 1, wherein the spacer is made of an insulating material of the same kind or different kind of resin, and is integrated into the coil together with the resin by resin injection. Method.   A plurality of coil arrangement spaces are provided in the mold, and a plurality of coils are arranged in the plurality of coil arrangement spaces, thereby applying a resin coating to the plurality of coils at one time. The method for producing a molded coil according to any one of 6.   The molded coil manufactured by the manufacturing method of the molded coil as described in any one of Claims 1-7.

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