JP2013135057A - Method and apparatus for producing resin burying metal component - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method and an apparatus which can perform heat hardening of a resin material at high speed and uniformly when producing a resin burying metal component in which a metal component is buried in a thermoset resin.SOLUTION: In order to produce a reactor R obtained by packing magnetic powder and a thermoset resin which are to be a dust core R2 and burying a coil R in a container shape metal housing R3 with the top edge opening, there are provided a first heating apparatus 1 having a cover plate 11 covering the housing R3 and a hot wind feed section 14, a second heating apparatus 2 performing high-frequency induction heating by using an iron plate 24 on which the housing R3 is placed and a heating coil 2, and a third heating apparatus 3 having an electric conduction path 31 for electrically heating the coil R. A heating control apparatus 4 controls the apparatuses independently, and at first the surface of the thermoset resin is heated and cured by the first heating apparatus 1 and then other apparatuses are operated so that the entire thermoset resin is heated uniformly and quickly.

Description

  The present invention relates to a method and an apparatus for manufacturing a resin-embedded metal part, for example, an electrical part in which a coil, various elements, and the like are embedded in a metal housing at high speed and soaking.

  There are electrical components for in-vehicle devices, for example, a reactor that is a coil component for a booster circuit, which is constituted by a coil and a dust core. The dust core is made of a thermosetting resin mixed with magnetic powder, and a resin-embedded coil component is manufactured by filling the dust core material into a metal housing, inserting a coil, and heating in a furnace. . Moreover, not only a coil but the electrical component of the structure which embed | buried the metal component in resin, and other resin-embedded metal components can be manufactured in the same process.

  However, when such a resin-embedded metal part is manufactured using a general furnace, there is a problem that the heat treatment time becomes long and the productivity is poor. As a solution, various heating methods have been proposed. For example, Patent Document 1 discloses a core material and a coil in which magnetic powder is dispersed in a thermosetting resin as an example of a reactor manufacturing method using a dust core. It is disclosed that a step of housing in a metal case and a step of curing the thermosetting resin by heating the metal case or magnetic powder by high frequency induction heating.

  On the other hand, Patent Document 2 discloses various methods such as a hot air heating method, an induction heating method, an infrared heating method, and a microwave heating method as means for heating and curing a thermosetting resin. Specifically, it is described that a baking furnace provided with a microwave generator as a heat source is used, and that a hot air heating apparatus and an induction heating apparatus are additionally provided in the baking furnace.

JP 2010-238853 A Japanese Patent Laid-Open No. 7-275776

  In the method using high frequency induction heating as in Patent Document 1, the metal case can be directly heated, and the temperature can be raised in a relatively short time to a temperature at which the thermosetting resin is cured. However, a temperature difference is likely to occur between a portion close to and far from the metal case, and it is difficult to uniformly heat the whole. Then, like patent document 2, the hybrid heating method which combined several heating means is examined.

  However, it has been found that even when the hybrid heating method is employed, it is difficult to completely eliminate the temperature difference, and the heat curing time cannot be significantly shortened. This is because there is a variation in temperature rise by each heating means, and because the shape is accommodated in a container-shaped metal housing, a portion that is easily heated and a portion that is easy to dissipate heat are generated, so that the temperature can be equalized. Presumed to be difficult.

  Accordingly, an object of the present invention is to produce a resin-embedded metal part having a structure in which the metal part is embedded in a thermosetting resin, and a method and an apparatus capable of performing heat curing of the resin material at high speed and soaking. It is to provide a high-quality resin-embedded metal part that can be manufactured with high efficiency by shortening the heat-curing time and cost can be reduced.

The invention according to claim 1 of the present invention is a method of manufacturing a resin-embedded metal part in which a thermosetting resin is filled in a container-shaped metal housing having an open upper end, and the metal part is buried.
A step of heat-curing the surface of the thermosetting resin exposed on the upper end opening side of the metal housing; and the heating of the metal housing and the metal component after the start of heating by the step to start the thermosetting resin And the step of heat-curing the whole.

The invention according to claim 2 of the present invention is an apparatus for producing a resin-embedded metal part in which a thermosetting resin is filled in a container-shaped metal housing having an open upper end, and the metal part is buried.
First heating means for heating the surface of the thermosetting resin exposed on the upper end opening side of the metal housing;
A second heating means disposed on the bottom side of the metal housing for heating the metal housing;
A third heating means for directly heating the metal part;
A heating control means for independently controlling these first to third heating means;
The heating control means operates the first heating means to heat the surface of the thermosetting resin, and after the surface temperature reaches a predetermined temperature lower than the curing temperature of the thermosetting resin, the first heating means is used. Control for operating the second heating means and the third heating means is performed.

  According to a third aspect of the present invention, the first heating means includes a cover body that covers the metal housing and hot air supply means that supplies hot air into the cover body.

  In the invention according to claim 4 of the present invention, the hot air supply means of the first heating means includes a metal gas introduction pipe connected to the cover body, and the gas introduction pipe is heated by high frequency induction heating. Induction heating means is provided.

  In the invention according to claim 5 of the present invention, the second heating means has a placement portion on which the metal housing is placed, and the placement portion or the metal housing is subjected to high frequency induction heating. Induction heating means for heating is provided.

  In the invention according to claim 6 of the present invention, the resin-embedded metal part is an electric part in which the metal part has a terminal part, and the third heating means is heated by energizing the terminal part of the metal part. It has an energization heating means.

  The invention of claim 1 focuses on the fact that heat release into the air is suppressed when the thermosetting resin is solidified. That is, first, a step of heating and curing the surface of the thermosetting resin exposed on the upper end opening side of the metal housing is performed to suppress heat radiation from the surface of the thermosetting resin. In this state, by carrying out the step of heating the metal housing and the metal part, the surrounding thermosetting resin can be heated with the heat applied thereto, and the whole can be quickly heated to the curing temperature. Therefore, as a result, the thermosetting resin can be heat-cured at high speed and soaking, the time required for resin embedding can be shortened, and high-quality resin-embedded metal parts can be manufactured at low cost.

  The invention of claim 2 is an apparatus for carrying out the invention of claim 1, and is a first heating means for heating the surface of the thermosetting resin, a second heating means for heating the metal housing, A third heating means for directly heating the metal part is provided so that the heating can be controlled independently of each other. The heating control means first starts heating by the first heating means, and operates the second and third heating means when the surface temperature of the thermosetting resin reaches a predetermined temperature near or slightly lower than the curing temperature. Let As a result, the surface of the thermosetting resin is cured first, the heat by the second and third heating means is confined, and the whole is quickly raised to the curing temperature. Therefore, the thermosetting resin can be heat-cured at high speed and soaking, the time required for resin embedding can be shortened, and high-quality resin-embedded metal parts can be manufactured at low cost.

  In the invention described in claim 3, specifically, as the first heating means, a hot air supply means for supplying hot air to the inside thereof is provided while a cover body covering the metal housing is provided to suppress heat radiation. Thus, the exposed surface of the thermosetting resin can be effectively heated.

  In the invention described in claim 4, the hot air supply means specifically includes a metal gas introduction pipe and induction heating means connected to the cover body, and quickly heats the introduced gas or the like. Thus, hot air can be supplied to the exposed surface of the thermosetting resin.

  In the fifth aspect of the invention, specifically, the second heating means heats the metal housing directly by high-frequency induction heating through a mounting portion on which the metal housing is mounted. Thereby, a metal housing can be heated rapidly and the thermosetting resin of the circumference | surroundings can be efficiently heat-hardened.

  Specifically, in the invention according to claim 6, the resin-embedded metal part may be an electric part having a terminal part. At this time, since the third heating means directly heats the metal part by the energization heating means connected to the terminal portion, the thermosetting resin around the metal part can be efficiently heat-cured.

BRIEF DESCRIPTION OF THE DRAWINGS It is 1st Embodiment to which this invention is applied, (a) is a whole schematic block diagram of the manufacturing apparatus of resin embedding metal components, (b) is a schematic block diagram which shows the connection structure of a heating control apparatus and a power supply. It is a perspective view which shows the example of a shape of the cover plate and reactor which comprise a 1st heating apparatus. It is a temperature increase characteristic diagram for demonstrating the control method of the heating control apparatus in the manufacturing apparatus of 1st Embodiment. It is a flowchart figure for demonstrating the control process of the heating control apparatus in the manufacturing apparatus of 1st Embodiment. (A) is a figure explaining the coil heating test method by furnace heating, (b) is a temperature-rise characteristic figure by furnace heating. (A) is a figure explaining the coil heating test method by electrical heating, (b) is a temperature rise characteristic diagram by electrical heating. (A) is a figure explaining the workpiece heating test method by high frequency heating, (b) is a temperature rise characteristic diagram by IH heating. (A) is a figure explaining the workpiece | work heating test method by electric heating, (b) is a temperature increase characteristic figure by electric heating. (A) is a figure explaining the workpiece | work heating test method by high frequency heating and electrical heating, (b) is a temperature rise characteristic figure by IH heating and electrical heating. (A) is a schematic block diagram of the testing apparatus by high frequency heating and electric heating.

  Hereinafter, a first embodiment of the present invention will be described in detail with reference to the drawings. FIG. 1A is a manufacturing apparatus for resin-embedded metal parts to which the present invention is applied, and shows a schematic configuration of the entire apparatus. In the present invention, the resin-embedded metal part is a part in which a metal part is embedded in a metal housing using a thermosetting resin. For example, a metal part that can be electrically connected such as a coil or various elements is embedded in the resin. Examples include electrical parts. In the present embodiment, a reactor R shown in the figure is manufactured as an example of a coil component in which a coil is embedded in a resin. The reactor R can be used for, for example, a booster mechanism provided in an inverter of an in-vehicle device.

  The reactor R includes a cylindrical coil R1, a dust core R2 filled in the inner and outer peripheries thereof, and a metal housing R3 in which the coil R1 and the dust core R2 are accommodated. The coil R1 is formed by winding a rectangular copper wire into a predetermined cylindrical body, for example, and has a pair of terminal portions C1 and C2 at its upper end. The metal housing R3 has a cylindrical container shape whose upper end is open, and can be made of aluminum having good thermal conductivity, for example. The dust core R2 is obtained by dispersing magnetic powder in a thermosetting resin. An uncured magnetic powder mixed resin is injected as a dust core material into a metal housing R3, and is cured by heating. Buried.

  The apparatus for producing a resin-embedded metal part of the present invention is used in a step of heat-curing a magnetic powder mixed resin constituting the dust core R2. The thermosetting resin material used as the magnetic powder mixed resin is not particularly limited. For example, an epoxy thermosetting resin is preferably used, and is cured by heating to a temperature higher than the thermosetting temperature. However, the dust core R2 is accommodated together with the metal coil R1 in the metal housing R3 whose upper end is opened, and the surface of the magnetic powder mixed resin that becomes the dust core R2 is exposed at the upper end opening of the metal housing R3. It becomes a subject to heat the whole uniformly from being heated.

  Therefore, in FIG. 1A, the manufacturing apparatus of the present embodiment is mainly composed of a first heating apparatus 1 which is a first heating means for accelerating the heat curing of the exposed surface of the dust core R2, and a metal made mainly. A second heating device 2 as a second heating means for heating the housing R3 and a third heating device 3 as a third heating means for mainly directly heating the coil R1 are provided. The first heating device 1 includes hot air supply means for supplying hot air into the cover plate 11 through a cover plate 11 as a cover body covering the entire reactor R and an air hose 12 as a gas introduction pipe connected to the cover plate 11. .

  Specifically, the hot air supply unit 14 as hot air supply means has an air hose 12 made of an iron-based metal tube and a heating coil 13 as induction heating means surrounding the outer periphery thereof. (IH power supply: IH (1)) 15 is connected. In the hot air supply unit 14, the alternating magnetic flux formed by the alternating current penetrates the air hose 12 to induce eddy current, and the surface of the air hose 12 is heated by the Joule heat. As a result, the air passing through the heated air hose 12 is heated and supplied to the inner space 16 of the cover plate 11 as hot air.

  As shown in FIG. 2, the metal housing R3 has, for example, a shape having a substantially Ω-shaped outer shape, and the cover plate 11 of the first heating device 1 has a substantially U-shaped outer shape covering the whole along the outer shape. Have. On the upper surface of the cover plate 11, a pair of through holes 11a and 11b are formed at positions corresponding to the terminal portions C1 and C2 of the coil 11. Thus, as shown in FIG. 1, when the cover plate 11 is covered, the terminal portions R11 and R12 of the coil R1 protrude out of the cover plate 11 from the pair of through holes 11a and 11b.

  The size of the cover plate 11 is such that the terminal portions R11 and R12 projecting outside the cover plate 11 have a predetermined height, and a predetermined gap through which hot air can flow is provided between the upper end surface or the side surfaces of the reactor 1. As formed, dimensions such as height and width can be set as appropriate. Preferably, the cover plate 11 may be formed small in a range that does not hinder the flow of hot air in the inner space 16 of the cover plate 11. Thereby, the surface of the dust core 12 exposed to the upper end surface of the reactor 1 is efficiently heated by the hot air introduced into the inner space 16 of the cover plate 11, the heat radiation from the surface is suppressed, and the thermosetting resin is cured. Can be promoted. Moreover, the reactor 1 whole can be heated moderately and efficiently with the hot air of the space 16 in the cover plate 11. The temperature of the hot air is preferably set to be slightly higher than the curing temperature so that the surface of the dust core 12 is equal to or higher than the curing temperature of the thermosetting resin.

  The 2nd heating apparatus 2 is provided with the mounting part 21 in which metal housing R3 is mounted. The mounting portion 21 has a heating coil 22 as induction heating means and an iron plate 24 made of an iron-based material disposed on the upper surface of the heating coil 22 via a plate-like heat insulating material 23. A high frequency power source (IH power source: IH (2)) 25 is connected to the heating coil 22. The second heating device 2 heats the metal housing R3 via the mounting portion 21, and indirectly heats the thermosetting resin of the dust core R2 that is in contact with the inner periphery of the metal housing R3.

  When the metal housing R3 is made of a low resistance material such as aluminum as in the present embodiment, it is preferable to interpose an iron plate 24 having a high metal resistivity. Thereby, the iron plate 24 is heated with the heating coil 22, and the metal housing R3 that is in close contact with the upper surface of the iron plate 25 can be indirectly heated efficiently. Moreover, in this embodiment, the magnetic powder which is a dust core material can be directly heated by high frequency induction heating, and heating efficiency can be improved. The heat insulating material 23 is installed in order to effectively introduce the heat generated by the high frequency induction heating into the metal housing R3 so as not to escape to the bottom surface side of the mounting portion 21. When the metal housing R3 is made of a metal material having a relatively high specific resistance, the iron plate 24 can be omitted and the metal housing R3 can be directly induction heated.

  The third heating device 3 includes an energization path 31 for energizing the terminal portions R11 and R12 of the coil R1 protruding upward from the cover plate 11 and a DC power source (C) 32, and constitutes an energization heating means. . The third heating device 3 of the present embodiment can directly heat the coil R1 with heat generated by the internal resistance when the coil R1 is energized using the terminal portions R11 and R12 of the coil R1 that is a metal part. It is possible to efficiently heat the dust core R2 in contact with the inner and outer circumferences.

  As shown in FIG. 1B, the high-frequency power source 15 of the first heating device 1, the high-frequency power source 25 of the second heating device 2, and the DC power source 32 of the third heating device 3 are each a heating control means. It is connected to the device 4. The energization from these power sources 15, 25, 32 to each device 1, 2, 3 can be independently controlled by the heating control device 4 via the isolation amplifier 41. In the present invention, on / off of the power sources 15, 25, and 32 is independently controlled by the heating control device 4 to adjust the temperature rising speed of each part of the dust core R 2 that is the object to be heated so that the whole is heated evenly. Control.

  Next, the heating control method in the manufacturing apparatus of the present invention will be described in detail with reference to FIGS. FIG. 3 shows the relationship between the energization timing of the heating control device 4 and the temperature rise of each part of the dust core R2. FIG. 4 is a flowchart showing the control process by the heating control device 4. In FIG. 1A, the temperature of each part of the dust core R2 is the temperature T0 at the upper end surface of the resin, the temperature T1 at the center of the resin, and the outer circumference of the resin in a state where the magnetic powder mixed resin that becomes the dust core R2 is injected into the metal housing R3. As means for detecting the temperature T2 of the part and the temperature T3 of the resin bottom surface, a thermocouple (not shown) was arranged and measured. In FIG. 1B, signals from these thermocouples are input to the heating control device 4 via the thermocouple amplifier 42.

  In FIG. 4, when control by the heating control device 4 is started in step 1, first, in step 2, the high frequency power supply 15 of the first heating device 1 is turned on, and high frequency induction heating by the heating coil 13 is started. At this time, the air hose 12 on the inner periphery of the heating coil 13 is heated, and the air passing through the inside is supplied as hot air to raise the temperature of the inner space 16 of the cover plate 11. In the reactor R in the inner space 16 of the cover plate 11, the temperature T0 of the upper end surface of the resin to which hot air is directly supplied immediately rises and quickly rises to the vicinity of the thermosetting temperature (for example, around 150 ° C.).

  Therefore, in step 3, it is determined whether or not the temperature T0 of the resin upper end surface has reached a predetermined temperature T near the thermosetting temperature, and if an affirmative determination is made, the process proceeds to steps 4 and 5 (time point a in the figure). Here, the predetermined temperature T is, for example, a preset temperature increase target temperature based on a rising curve of the temperature T0 of the resin upper end surface by the first heating device 1, and the first heating device 1 will be referred to as the predetermined temperature thereafter. Controlled to maintain T.

  At this time point a, the temperature T0 on the upper end surface of the resin is the highest, but the temperature inside the resin heated via the metal housing R3 also increases with a moderate temperature rise curve (temperature T3 on the resin bottom surface> resin Temperature T2 at the outer periphery> T1 at the center of the resin). Therefore, in step 4, the high frequency power supply 25 of the second heating device 2 is turned on to start high frequency induction heating by the heating coil 22, and in step 5, the DC power supply 32 of the third heating device 3 is turned on to turn on the coil R13. When the current is heated by energization, the temperature of other parts also rises quickly.

  That is, the high-frequency induction heating of the second heating device 2 further increases the temperature T3 of the resin bottom surface in contact with the metal housing R3, and the resin center portion in contact with the inner and outer circumferences of the coil R1 by the current heating of the third heating device 3 The temperature T1 of the resin and the temperature T2 of the outer periphery of the resin rise rapidly and converge to a predetermined temperature T near the thermosetting temperature. In Step 6, when it is determined that the temperatures at these three locations (the temperature T1 at the center of the resin, the temperature T2 at the outer periphery of the resin, and the temperature T3 at the bottom of the resin) are uniform within a predetermined variation range (time point) b) Proceed to Step 7 and stop all heating of the first heating device 1, the second heating device 2, and the third heating device 3. Then, the reactor 1 by which coil R1 was embed | buried under the dust core R2 can be manufactured by natural cooling.

  As described above, the heating control device 4 of the present invention uses the first heating device 1 to first heat and cure the resin upper end surface exposed from the upper end opening of the metal housing R3, and then the second heating device 2 and the second heating device. 3 Heating of the heating device 3 is started. As a result, as shown in FIG. 3, the time required to heat and cure the upper end surface of the resin that becomes the dust core R2 is significantly shortened (for example, 1 minute or less), and each part of the resin that becomes the dust core R2 is quickly raised to a predetermined temperature T. In addition, the temperature variation at the time point b was reduced (for example, about ± 10 ° C.), and the entire dust core R2 could be heated uniformly.

  Here, the predetermined temperature T can be set to a temperature lower than the temperature increase target temperature corresponding to the time point a. For example, when the temperature of each part after the operation of the second heating device 2 and the third heating device 3 rises with a gentler temperature rise curve, at a predetermined temperature T ′ corresponding to a time point a ′ faster than the time point a. By starting the temperature increase, it is possible to shorten the time until convergence to the target temperature. Further, it is not necessary to determine whether or not the predetermined temperature T has been reached by providing a temperature detection means such as a thermocouple, and the energization timing is set so that the heating is started at the time point a when the predetermined temperature T is reached from the previously known temperature rise characteristic. Can also be set.

  In addition, the energization timings of the second heating device 2 and the third heating device 3 do not have to be simultaneous or continuous, and the timing may be shifted or the order may be reversed. The first heating device 1, the second heating device 2, and the third heating device 3 can be independently controlled, and at a predetermined time point b, each temperature rise characteristic is set so that the variation in temperature of each part converges to a predetermined range. Accordingly, an optimum energization timing may be set.

  The present invention focuses on the fact that heat release into the air is suppressed when the thermosetting resin is solidified, which is presumed to be because the heat transfer coefficient changes when the thermosetting resin is heat-cured. Is done. That is, the heat given from the metal housing R3 and the coil R1 is heated by the second heating device 2 and the third heating device 3 while curing the upper end surface of the resin in contact with air and suppressing heat dissipation. Is unlikely to be released to the outside, making it possible to efficiently distribute heat to the entire thermosetting resin. As a result, it is possible to heat and cure the dust core R2 at high speed and soaking, improve the quality of the dust core R2, shorten the time required for molding, and reduce the manufacturing cost.

  For comparison, FIG. 5 shows the temperature rise characteristics when a conventional general furnace is used. As shown in FIG. 5A, only the coil R1 was used as a workpiece. As shown in the figure, the temperature T01 of the furnace is set to 170 ° C., which is higher than the curing temperature of the thermosetting resin used for the dust core R2, the coil R1 is accommodated, and the temperature T02 to T06 of each part inside and outside the coil is measured. As shown in FIG. As shown in the drawing, the temperature variation of each part of the coil is large, and the temperature is lower toward the outer peripheral side or the bottom side. Further, it takes time to increase the temperature, and it is difficult to increase the temperature to around 150 ° C. except for the inner and outer connecting wires (T02, T03) of the coil R1 that becomes the terminal portions R11, R12.

  Further, FIG. 6 shows the temperature rise characteristics when energization heating is used. As shown in FIG. 6A, the work is only the coil R1, and a predetermined constant current is supplied from the DC power source to the terminal portions R11 and R12. Was applied. Similarly to FIG. 5, the results of measuring the temperatures T02 to T06 of the respective parts inside and outside the coil from the start of energization are shown in FIG. 6 (b). As shown in the figure, the temperature of each part of the coil rapidly increases after a certain time from the start of energization, but the temperature variation of each part gradually increases. In addition, the temperature increases toward the outer peripheral side or the bottom surface side, and exceeds 150 ° C. at the central portion (T05, T06) outside the coil.

  Further, FIG. 7 shows the result of a similar temperature increase test in the configuration of FIG. 1 when only the high frequency induction heating by the second heating device 2 is used. The workpiece is an actual workpiece having an actual reactor R configuration, the temperatures TH1 and TH3 to TH4 of the inner parts of the coil R1 shown in the figure, the upper and lower temperatures TH2 and TH5 of the thermosetting resin used for the dust core R1, and made of metal The result of having measured temperature TH6 of the lower part of housing R3 is shown. As shown in the drawing, except for the housing lower part temperature TH6 in contact with the mounting portion 21 of the second heating device 2, the temperature hardly rises, and the housing lower part temperature TH6 also rises moderately and does not reach the resin curing temperature alone.

  FIG. 8 shows the results of a temperature increase test performed on an actual work having an actual reactor R configuration using the same energization heating as that in FIG. As shown in the figure, the temperature of each part (TH1, TH3, TH4) of the coil R2 is increased similarly to FIG. 6, but the lower temperature TH5 of the thermosetting resin and the temperature TH6 of the lower part of the metal housing R3 are: The temperature rise is small and uniform heating is difficult by itself.

  FIG. 9 shows a result of a temperature increase test performed on an actual work having an actual reactor R configuration by combining the high frequency induction heating of FIG. 7 and the energization heating of FIG. FIG. 10 is a schematic diagram showing the configuration of the apparatus in this example. The first heating apparatus 1 in the first embodiment of FIG. 1 is not provided, and the reactor R is connected by the second heating apparatus 2 and the third heating apparatus 3. It comes to heat. As shown in the figure, although temperature rise is observed at each part of the actual work, particularly at the lower side (coil inner lower temperature TH3, housing lower temperature TH6, resin lower temperature TH5), the temperature variation is large. Further, at the inner center temperature TH1 of the upper coil R2, the temperature rise is small, and it can be seen that uniform heating is difficult simply by combining two heating means.

  In addition, the manufacturing apparatus of the said 1st Embodiment uses the 2nd heating apparatus 2 which used the high frequency induction in order to heat metal housing R3 so that it may become the optimal for the structure and material of the reactor R which is a heating object, In order to directly heat the coil R1, which is a metal part, the third heating device 3 using current heating is provided, but when applied to electrical parts other than the coil parts and other resin-embedded metal parts, Any heating means can be selected according to the characteristics. For example, when the metal part has a film that absorbs microwaves, the third heating device 3 using microwave heating can be installed.

  As described above, according to the present invention, the surface of the thermosetting resin that easily dissipates heat is first cured using the first heating device 1, and then the second heating device 2 and the third heating device 3 are used. By heating the metal housing and the metal parts, the entire thermosetting resin can be soaked at high speed. If the metal part used for the resin-embedded metal part can be heated by, for example, the second heating device 2 that heats the metal housing R3, the third heating device 3 is integrated with the second heating device 2, A common heating device can also be used.

  The method and apparatus for producing a resin-embedded metal part according to the present invention can be applied not only to a reactor but also to a coil part used as a transformer or the like, and other electrical parts. Furthermore, not only electrical components but also products having a structure in which metal components are embedded in a resin can be suitably used.

R reactor (coil parts, resin-embedded metal parts)
R1 coil (metal parts)
R2 dust core (thermosetting resin)
R3 metal housing 1 first heating device (first heating means)
11 Cover plate (cover body)
12 Air hose (gas supply pipe)
13 Heating coil (induction heating means)
14 Hot air supply part (hot air supply means)
15 High-frequency power source 2 Second heating device (second heating means)
21 mounting part 22 heating coil (induction heating means)
23 heat insulating material 24 iron plate 25 high frequency power source 3 third heating device (third heating means)
31 Current path 32 DC power supply 4 Heating control device (heating control means)

Claims (6)

A method for producing a resin-embedded metal part in which a thermosetting resin is filled in a container-shaped metal housing having an open upper end, and a metal part is buried,
A step of heat-curing the surface of the thermosetting resin exposed on the upper end opening side of the metal housing; and the heating of the metal housing and the metal part after the start of heating by the step to heat the entire thermosetting resin And a step of heat-hardening the resin-embedded metal part. An apparatus for manufacturing a resin-embedded metal part in which a thermosetting resin is filled in a container-shaped metal housing having an open upper end, and a metal part is embedded,
First heating means for heating the surface of the thermosetting resin exposed on the upper end opening side of the metal housing;
A second heating means disposed on the bottom side of the metal housing for heating the metal housing;
A third heating means for directly heating the metal part;
A heating control means for independently controlling these first to third heating means;
The heating control means activates the first heating means to heat the surface of the thermosetting resin, and after the surface temperature reaches a predetermined temperature lower than the curing temperature of the thermosetting resin, An apparatus for manufacturing a resin-embedded metal part, wherein control is performed to operate the second and third heating means.   The apparatus for manufacturing a resin-embedded metal part according to claim 2, wherein the first heating means includes a cover body that covers the metal housing and hot air supply means that supplies hot air into the cover body.   The hot air supply means of the first heating means includes a metal gas introduction pipe connected to the cover body and induction heating means for heating the gas introduction pipe by high frequency induction heating. 3. The apparatus for producing a resin-embedded metal part according to 3.   The second heating means includes a placement portion on which the metal housing is placed, and includes induction heating means for heating the placement portion or the metal housing by high frequency induction heating. 5. The apparatus for producing a resin-embedded metal part according to any one of items 4 to 4. 3. The resin-embedded metal part is an electric part having the terminal part of the metal part, and the third heating means has an electric heating means for heating by energizing the terminal part of the metal part. The manufacturing apparatus of the resin-embedded metal part of any one of thru | or 5.

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