JP2015122484A - Coil, manufacturing method thereof, and reactor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To easily manufacture an electronic component of a reactor or the like by combining a coil with a core or the like while using a self-fusing layer of the coil.SOLUTION: The coil includes a coil body 1 formed from a flat wire with which a self-fusing layer is formed on a surface, and resin members 2a and 2b mounted in both axial end portions of the coil body 1. While mounting the resin members 2a and 2b, the coil body 1 is pressurized in the axial direction of the coil body 1 by a pressing member abutted to the resin members. The self-fusing layer on the surface of the flat wire is heated and fused, such that neighboring flat wires are bonded with each other. Each of the resin members 2a and 2b includes: an end face plate 21 abutted to an end face of the coil body 1, an edge plate 22, a positioning pin and a fixing bracket.

Description

  The present invention relates to a coil formed by winding a wire having a self-bonding layer formed on its surface, a manufacturing method thereof, and a reactor.

  The edgewise coil is a coil that is wound vertically with the short side of a flat wire as the inner diameter surface, and has a larger winding cross-sectional area and a higher space factor than a coil wound with a round wire because the cross section is a corner. Further, unlike a round wire, it is not wound in multiple layers, and only one layer is required, so that the temperature difference between the inside and outside of the winding is small, the heat dissipation performance is excellent, and the temperature rise is small. Because of such advantages, it is suitable as a coil for a high-efficiency reactor.

  Conventionally, as one of the edgewise coils, a self-bonding layer made of a thermosetting resin or the like is formed on the surface of a flat wire or a flat knitted wire, and the wound coil is heated to heat the winding. An integrated self-bonding edgewise coil is known (see Patent Document 1 and Patent Document 2). Here, “self-bonding” means that the resin formed on the surface of the wire itself is melted by heating the wire without requiring any other adhesive or molding resin, and the adjacent wire It means to be glued. As the resin for forming the self-bonding layer, a phenol resin, an epoxy resin, a polyimide resin, a resin obtained by converting a part of the epoxy resin into a phenol resin, or the like is used.

  Compared to the conventional technology in which a self-bonding type edgewise coil is integrated by impregnating or resin-molding a coil wound with a flat wire, by using a flat wire having a self-bonding layer, The complexity of the process and the risk of damaging the coating of the wire during mold molding can be eliminated.

JP 2009-200237 A JP 2009-261086 A Table 2008/096526

  An edgewise coil wound with a rectangular wire having a self-bonding layer does not have much tightening force (residual stress). Force acting in the direction) does not develop, and the wires cannot be reliably bonded to each other simply by heating the coil. For this reason, Patent Documents 1 and 2 propose a technique in which adjacent wire members are bonded together by applying pressure from the axial direction of the coil in a state where the wound coil is set in a mold or the like.

  However, in the conventional technique, since the wound coil is directly pressed by the mold, the self-bonding layer on the surface of the wire sticks to the mold, and it is difficult to take out from the mold. In addition, edgewise coils are not used alone, and are combined with a core and its bobbin to constitute a reactor and other electronic components. Even if they are integrated, if the combination work with the core and the bobbin is further performed thereafter, the number of manufacturing steps of the electronic component increases. For example, when the bonding between the coil and another member other than the coil is separately performed using an adhesive or the like, the number of manufacturing steps increases by the number of steps for bonding using the adhesive.

  The difficulty of taking out from the mold and the increase in the number of manufacturing steps are not limited to the edgewise coil, and the same problem may occur in other coils.

  The present invention has been proposed to solve the above-described problems of the prior art. It is an object of the present invention to prevent a self-bonding layer from adhering to a mold at the time of pressurization, to easily perform a wire-bonding operation, and to core a coil in which a wire is integrated by fusion. Another object of the present invention is to provide a coil that can easily manufacture electronic components such as a reactor in combination with a bobbin, a manufacturing method thereof, and a reactor.

In order to achieve the above object, the coil of the present invention has the following configuration. Moreover, the manufacturing method of the coil which has the following characteristics is also 1 aspect of this invention.
(1) A coil body comprising a wire and a self-bonding layer formed on the surface of the wire.
(2) A resin member fixed to the wire.
(3) The wire is bonded and fixed to the resin member by the self-bonding layer.

The coil of the present invention may have the following configuration. Moreover, the manufacturing method of the coil which has the following characteristics is also 1 aspect of this invention.
(4) The coil body is an edgewise coil around which a rectangular wire as the wire is wound.
(5) The resin member is attached to the axial end of the coil body.
(6) The coil body is pressurized from the axial direction of the coil body through the resin member in a state where the resin member is mounted.
(7) The self-bonding layer on the surface of the rectangular wire is heated and melted, and adjacent portions of the wound rectangular wire are bonded to each other.

  The resin member may be attached to both ends of the coil body.

  A protrusion protruding from the surface of the rectangular wire may be formed on at least a part of the coil body, and the protruding portion may be bonded to an adjacent portion of the rectangular wire by a self-bonding layer.

  A protrusion protruding from the surface of the rectangular wire is formed on at least a part of the coil body, and the protrusion is crushed by being pressed from the axial direction of the coil body after the winding of the rectangular wire. In addition, adjacent portions of the flat wire may be bonded by a self-bonding layer.

  The coil body is formed with a protrusion protruding from the surface of the rectangular wire on at least a part of the inner periphery of the bent portion, and is pressed from the axial direction of the coil body after the winding of the rectangular wire. Then, the protruding portion may be crushed and adjacent portions of the flat wire may be bonded to each other by a self-bonding layer.

  The coil body is formed by winding a flat wire with a flat surface so that the flat surfaces face each other, and adjacent portions of the flat wire are bonded to each other by at least a part of the flat surface by a self-bonding layer. May be.

  The resin member can be provided with a through-hole portion of a connection terminal protruding from an end portion of the coil body, a core inserted into the coil body, or a fixed portion of the resin member integrated with the core.

The reactor using the coil of this invention is a reactor provided with the core and the coil which has the structure of said (1)-(3), Comprising: It has the following structures.
(8) The core is embedded in the resin member.
(9) A positioning portion for positioning an end portion of the coil body is provided on the surface of the resin member in which the core is embedded.

Furthermore, the reactor using the coil of this invention may have the following structure.
(10) The self-bonding layer at the end of the wire rod is bonded to the positioning portion, and the wire rod of the coil body is fixed to the resin member.
(11) The positioning portion is a pair of protrusions protruding from the surface of the resin member, an end portion of the wire body of the coil body is sandwiched between the pair of protrusions, and the self-bonding layer is formed on the protrusions. Glued.

The reactor using the coil of this invention is a reactor provided with the core and the coil which has the structure of said (1)-(3), Comprising: It has the following structures.
(12) The core is embedded in the resin member.
(13) The end face of the coil body is bonded to the resin member by the self-bonding layer.

  ADVANTAGE OF THE INVENTION According to this invention, manufacture of electronic components, such as a reactor, can be made easy by combining a core etc. with the coil main body which has a self-fusion layer on the surface of a wire.

The perspective view of the edgewise coil of 1st Embodiment. The disassembled perspective view of the edgewise coil of 1st Embodiment. The disassembled perspective view which looked at the edgewise coil of FIG. 2 from the opposite direction. The perspective view of the reactor incorporating the edgewise coil of 1st Embodiment. The disassembled perspective view of the reactor incorporating the edgewise coil of 1st Embodiment. The perspective view of the edgewise coil of 2nd Embodiment. The disassembled perspective view of the reactor incorporating the edgewise coil of 2nd Embodiment. The exploded perspective view which looked at the reactor of FIG. 7 from the bottom face direction. It is a figure which shows the edgewise coil of 3rd Embodiment, (a) is a perspective view of the whole coil, (b) is sectional drawing of the laminated | stacked part of the flat wire which comprises a coil. It is a figure which shows the edgewise coil of 4th Embodiment, (a) is a perspective view of the whole coil, (b) is sectional drawing of the lamination | stacking part of the flat wire which comprises a coil. It is a top view of the coil which concerns on 5th Embodiment. It is a perspective view of the reactor incorporating the coil of 5th Embodiment. It is a disassembled perspective view of the reactor incorporating the coil of 5th Embodiment.

1. First Embodiment Hereinafter, a first embodiment of the present invention will be described in detail with reference to FIGS.

(1) Configuration The edgewise coil of the present embodiment is mounted on a cylindrical coil body 1 formed by winding a rectangular wire having a self-bonding layer formed on a surface thereof into a quadrangle, and both axial end faces of the coil body 1 The first and second resin members (referred to as coil-side resin members) 2a and 2b are formed. As the resin constituting the self-bonding layer, those used in conventional self-bonding electric wires can be used. You can use what you have. The coil side resin members 2a and 2b are made of a heat-resistant material higher than the adhesion temperature of the self-bonding layer. For example, epoxy resin, unsaturated polyester resin, urethane resin, BMC (Bulk Molding Compound), PPS (Polyphenylene) Sulphide; polyphenylene sulfide), PBT (Polybutylene Terephthalate) and the like. Moreover, when the resin of the self-bonding layer is an epoxy resin, PPS (product name: FZ-840-D1) manufactured by DIC is preferable. This is because the adhesiveness to the epoxy resin is high.

  The coil body 1 includes a pair of left and right winding portions 11a and 11b, lead portions 12a and 12b protruding from the first ends of the winding portions 11a and 11b, and winding portions 11a and 11b. A connecting portion 13 provided between the second end portions is provided. In the present embodiment, the lead-out portions 12a and 12b and the connection portion 13 are formed integrally with the winding portions 11a and 11b by bending one rectangular wire, but the two cylindrical windings are formed. Even if the lead portions 12a and 11b and the connection portion 13 are provided by separately forming the portions 11a and 11b and joining short lead wires separately prepared to these winding portions 11a and 11b by a method such as welding. good.

  The first coil side resin member 2a is mounted on the lead portions 12a and 12b side of the coil body 1. The first coil side resin member 2a includes an end face plate 21 covering a rounded rectangle (also called a track shape) covering the end face of the coil body 1, and an edge plate protruding from the outer edge of the end face plate 21 toward the coil body 1 side. 22 is provided. The end plate 21 has openings 23a and 23b for inserting the core of the reactor inside the pair of left and right winding parts 11a and 11b, and notches 24a and 24b for inserting the lead parts 12a and 12b above the openings 23a and 23b. Is provided. That is, the notches 24a and 24b serve as through portions through which the lead portions 12a and 12b protruding from the end of the coil body 1 pass. Thus, since the notches 24a and 24b are provided in a part of the end face plate 21, the lead portions 12a and 12b can be drawn and exposure of the end face of the coil body 1 can be suppressed.

  A triangular bracket 25 is provided on the lower edge of the end face plate 21 (on the side opposite to the lead portions 12a and 12b) so as to protrude horizontally on the side opposite to the coil body 1. A screw hole 26 used to fix the resin member on the core side when assembling the reactor is provided at the tip (a triangular apex portion) of the bracket 25. In the upper center of the end face plate 21, a recess 27 used for positioning the resin member on the core side is provided.

  The second coil side resin member 2b has the same structure as the first coil side resin member 2a, and includes a rounded rectangular end plate 21, an edge plate 22, openings 23a and 23b, and a recess 27. Yes.

(2) Manufacturing method The edgewise coil of this embodiment is manufactured as follows.
First, a rectangular wire having a self-bonding layer formed on its surface is edgewise wound to form a coil body 1 having left and right winding portions 11a and 11b and lead portions 12a and 12b shown in FIGS. In this case, the winding operation of the flat wire is performed at room temperature so that the self-bonding layer on the surface does not melt and the adjacent flat wire does not adhere. As a method of edgewise winding of a rectangular wire, a known technique can be appropriately selected and used. For example, the method described in Patent Document 3 can be used.

  After the coil main body 1 is formed, the coil side resin members 2a and 2b are covered on both ends, and the coil main body 1 is pressurized from the axial direction in a heated atmosphere at 170 to 200 ° C. in that state. In this case, a pressing jig such as a mold is brought into contact with the coil-side resin members 2a and 2b so that the coil body 1 and the pressing jig do not come into contact with each other. When the coil body 1 is pressurized in a heated atmosphere, the resin constituting the self-bonding layer is melted, adjacent rectangular wires are bonded together by the melted resin, and the entire coil is integrated.

  At this time, in this embodiment, the coil-side resin members 2a and 2b are made of PPS resin, and since this PPS resin has a high heat resistance of about 280 ° C., the melting temperature of the self-bonding layer. It will not be affected. Therefore, the pressurizing jig in contact with the coil-side resin members 2a and 2b can be easily applied from the surface of the coil-side resin members 2a and 2b after pressurization, despite the melting of the self-bonding layer of the coil body 1. You can leave. On the other hand, since the coil main body 1 and the coil side resin members 2a and 2b are bonded by the self-bonding layer of the coil main body 1, handling after pressurization becomes easy.

(3) Configuration of Reactor A reactor using the edgewise coil of the present embodiment will be described with reference to FIGS. 4 and 5. The reactor includes an edgewise coil according to the present embodiment including a coil body 1 and coil side resin members 2a and 2b, an annular core made of a magnetic material, and a resin member covering the annular core (referred to as a core side resin member). It is composed of

  The annular core includes first and second yoke portions (also called yoke portions) 3a and 3b each having a substantially C-shape, and two block-like leg portions 4a and 4b that connect the left and right, respectively. It is connected in a ring shape via 5a and 5b. The first and second yoke portions 3a and 3b are embedded in the first and second core-side resin members 6a and 6b, respectively, by a molding method. The left and right block-like leg portions 4a and 4b are inserted into the cylindrical bobbins 61a and 61b provided in the first and second core-side resin members 6a and 6b, respectively, and the coil-side resin members 2a and 2b are inserted. Are inserted inside the winding portions 11a and 11b of the coil body 1 through the openings 23a and 23b.

  A pin 62 that protrudes horizontally toward the edgewise coil side is provided at the center of the upper surface of the first core-side resin member 6a, and this pin 62 is inserted into the recess 27 of the coil-side resin member 2a. The upper positioning of the resin member 6a and the coil side resin member 2a is performed. Groove-shaped guides 63a and 63b are provided on the upper left and right sides of the first core side resin member 6a in accordance with the positions of the lead portions 12a and 12b of the coil body 1, and the lead portions 12a and 12b are inserted therein. Has been. That is, a groove for inserting the lead portions 12a and 12b is formed by two guides. The drawer portions 12a and 12b are positioned by the guides 63a and 63b.

  A horizontally projecting triangular bracket 64 is provided at the center of the lower portion of the first core side resin member 6a, and is opposed to the screw hole 26 of the coil side resin member 2a at the tip (the apex portion of the triangle) of the bracket 64. A screw hole 65 is provided. By fastening these screw holes 26 and 65 with the screws 7, the core side resin member 6a and the coil side resin member 2a are integrated. On both lower sides of the first core-side resin member 6a, screw holes 66a and 66b are provided for fixing the completed reactor to the case and other installation locations.

  Similarly to the first core-side resin member 6a, a pin 62 is provided at the center of the upper surface of the second core-side molded product 6b, and the pin 62 is inserted into the recess 27 of the coil-side resin member 2b. The upper side of the side resin member 6b and the coil side resin member 2b is positioned. A fixing fitting 8 is integrally fixed to the second core-side resin member 6b by a molding method. The fixing bracket 8 is a gate-shaped member, and an upper piece thereof is embedded in the second core-side resin member 6b. The lower end of the fixture 8 extends in the horizontal direction, and screw holes 81a and 81b for fixing the completed reactor to the case and other installation locations are provided at that portion.

(4) Effects The edgewise coil of the present embodiment is obtained by adhering adjacent rectangular wires by heating and pressing a rectangular wire on which a self-bonding layer is formed after edgewise winding. In addition, there is no need to separately prepare a molding resin or an adhesive, and the entire coil can be integrated by a simple operation. Further, the gap between the rectangular wires after winding is narrow and difficult to impregnate with resin or adhesive, but in this embodiment, since the self-bonding layer is formed on the flat wire surface in advance, the gap is narrow. In addition, there is a sufficient amount of the fusion resin, and it is possible to reliably join the rectangular wires.

  In particular, in the present embodiment, the coil body 1 is pressed in a state where the heat-resistant coil side resin members 2a and 2b are mounted on both sides of the coil body 1, so that a pressing jig such as a mold, a self-bonding layer, Will not touch. Therefore, the pressurizing jig is not fouled by the resin constituting the self-bonding layer, and the mold separation between the coil and the pressurizing jig is not deteriorated, and maintenance of the pressurizing jig is easy. .

  The coil-side resin members 2a and 2b of the present embodiment are not simply members that prevent contact between the pressing jig and the self-bonding layer, but the positioning recesses 27 and fixing screws of the core-side resin members 6a and 6b. Since the hole 26 is provided, it also functions as a member used to fix the edgewise coil to the core side resin members 6a and 6b. After the coil body 1 is self-fused, the coil side resin member 2a, The operation | work which mounts 2b to the coil main body 1 becomes unnecessary, and simplification of the manufacturing operation of a reactor can also be achieved. The bracket 25 provided with the fixing screw hole 26 serves as a fixing portion for fixing the core to be inserted into the coil body 1. That is, the bobbins 61a and 61b are disposed in the winding portions 11a and 11b with the block-like leg portions 4a and 4b inserted therein, and the coil side resin members 2a and 2b are connected to the coil side resin members 2a and 2b via the fixing screw holes 26. Since the core side resin members 6a and 6b are fixed, as a result, the core in the core side resin members 6a and 6b is fixed.

  The coil side resin members 2a and 2b are provided with an end face plate 21 and an edge plate 22, which protect the corner portion of the coil body 1 that is easily damaged during handling, and therefore has an advantage that the edgewise coil is less damaged. . By appropriately selecting the dimensions of the openings 23a and 23b provided in the end face plate 21, the inner peripheral edges of the openings 23a and 23b are guided when the core-side resin members 6a and 6b are inserted into the coil body 1. As a result, it is possible to prevent the coating on the inner surface of the coil body 1 from being damaged by the core side resin members 6a and 6b.

2. Second Embodiment A second embodiment of the present invention will be described with reference to FIGS. The same parts as those in the first embodiment are denoted by the same reference numerals, and description thereof is omitted.

  As shown in FIG. 6, in this embodiment, the 1st coil side resin member 2a is provided with the thin plate-shaped end surface board 21 which covers only the lower part of the end surface of right and left winding part 11a, 11b. The end face plate 21 is provided with edge plates 22a and 22b that enter the left and right winding portions 11a and 11b. The end face plate 21 is provided with a trapezoidal bracket 25 that protrudes horizontally in the opposite direction to the edge plates 22a and 22b at the same height as the edge plates 22a and 22b. When this bracket 25 comprises a reactor, it is inserted in a part (bottom part) of the core side resin member 6a, and has a shape that covers the bottom part of the core.

  When manufacturing the edgewise coil of the present embodiment, the end plate 21 of the first coil side resin member 2a and the end plate of the second coil side resin member 2b in a heating atmosphere in which the self-bonding layer melts. A pressurizing jig is brought into contact with 22 to pressurize the coil body 1 from the axial direction. As a result, similarly to the first embodiment, adjacent rectangular wires can be integrated without bringing a pressing jig into contact with the self-bonding layer of the coil body 1.

  As shown in FIG. 8, the reactor using the edgewise coil of the present embodiment has a trapezoidal opening 67 formed at the bottom of the first core-side resin member 6 a, and the first coil is formed in the opening 67. By fitting the trapezoidal bracket 25 provided on the side resin member 2a, the coil side resin member 2a and the core side resin member 6a are integrated.

  In the second core side resin member 6b of the reactor, as shown in FIG. 7, the gate-shaped fixing bracket 8 is not a resin mold, but two pins formed on the upper surface of the second core side resin member 6b. 68a and 68b are locked by being inserted into a pair of locking holes 82a and 82b provided in the fixture 8. A resin cover 9 is fixed to the upper surface of the fixture 8 by pins 68 a and 68 b and locking holes 93 a and 93 b provided in the cover 9.

  According to the present embodiment, the bracket 25 provided on the first coil-side resin member 2a is simply fitted into the opening 67 of the coil-side resin member 6a, so that both are integrated. Fixing work is simpler than screwing. Further, since the first coil side resin member 2a is small and constitutes a part of the second core side resin member 6a, there is an advantage that the amount of resin used in the entire reactor is small.

3. 3rd Embodiment 3rd Embodiment is described according to Fig.9 (a) (b). As described in Patent Document 2, since the edgewise coil using a conventional rectangular wire is in close contact with the adjacent portion of the rectangular wire, it is difficult to dissipate heat from the adjacent portion of the rectangular wire, There was a problem that heat was trapped in the coil. On the other hand, in this embodiment, as shown in the cross-sectional view of FIG. 9B, the coil body 1 has a flat wire surface L on the inner periphery of the bent portion R positioned at the four corners of the winding portions 11a and 11b. The protrusion part W protruded from is formed, and is bonded to the rectangular wire adjacent to the protrusion part W by the self-bonding layer. That is, the protrusion W is bonded to the portion of the flat wire adjacent to the protrusion W by the self-bonding layer. Therefore, adjacent rectangular wires are joined in the form of dots at the four corners of the inner periphery of the coil, and between the surfaces of adjacent rectangular wires, the height of the protrusion W is about twice (the protrusions of both the rectangular wires are present). Therefore, a gap of about twice the height of the protruding portion is formed. This protrusion W is caused by the difference in arc between the inner periphery and the outer periphery of a rectangular wire when a rectangular wire having a certain width is wound edgewise, and is called bending bend, bending thickening, bending thinning, etc. As shown in FIG. 9B, a protrusion W that is thicker than the outer peripheral side is formed on the inner peripheral side of the rectangular wire, but in this embodiment, the generated protrusion W is positively To use.

  According to this embodiment, since a gap is formed between adjacent rectangular wires, when applied to a direct cooling reactor, the refrigerant passes through the gap between the rectangular wires, so that high heat dissipation performance can be expected. The coil body 1 of the present embodiment can be used in combination with the coil side resin members 2a and 2b as in the first embodiment and the second embodiment, but the coil body 1 alone is used as an edgewise coil. It is also possible. In that case, it is desirable to adopt means such as providing a cover that does not adhere to the self-bonding layer such as silicon resin at the tip of the pressing jig.

4). 4th Embodiment 4th Embodiment is described according to Fig.10 (a) (b). In the present embodiment, the coil body 1 is pressed from the axial direction of the coil after winding of the rectangular wire, so that the inner periphery of the bent portion R protrudes as shown in the sectional view of FIG. The portion is crushed to form a flat flat wire surface, and the adjacent flat wire is bonded to the entire surface by a self-bonding layer. This crushing process of the protrusions may be performed simultaneously with the heating and pressing process when performing the self-fusion, or may be performed only at normal temperature after winding the coil.

  According to the present embodiment, since the rectangular wire is bonded to the adjacent rectangular wire over the entire surface, it is possible to avoid extremely high adhesive strength and the risk of foreign matters entering the coil layers. There is also an advantage that the equivalent thermal conductivity in the winding axis direction is improved. The coil body 1 of the present embodiment can be used in combination with the coil side resin members 2a and 2b as in the first embodiment and the second embodiment, but the coil body 1 alone is used as an edgewise coil. It is also possible.

5. Fifth Embodiment (1) Configuration A coil according to a fifth embodiment and a reactor using the coil will be described with reference to FIGS. FIG. 11 is a plan view of a coil according to the present embodiment. FIG. 12 is a perspective view of the reactor according to the present embodiment. FIG. 13 is an exploded perspective view of the reactor according to the present embodiment. The same parts as those in the first embodiment are denoted by the same reference numerals.

  In the first embodiment, the coil side resin members 2a and 2b are used as the resin members to be attached to the coil body 1, and the coil side resin members 2a and 2b are distinguished from the core side resin members 6a and 6b. In the embodiment, instead of providing the coil side resin members 2a and 2b, the self-bonding layer of the coil body 1 is directly bonded to the resin member covering the core. Details will be described below.

  As shown in FIGS. 11 to 13, the reactor includes an annular core, a coil body 1, a resin member 6 bonded to the coil body 1, a terminal block 110 attached to the resin member 6, and a terminal block 110. Bus bars 111a and 111b provided in the vehicle.

  Similar to the first embodiment, the annular core is a magnetic body such as a dust core, a ferrite core, or a laminated steel plate, and is configured in an annular shape as a whole. The annular core has a plurality of split cores, and is composed of a pair of linear legs and a connecting part that connects the ends of the legs. In this embodiment, as in the first embodiment, the annular core is composed of block-like leg portions 4a and 4b that are linear leg portions, and first and second yokes that are substantially C-shaped and that are connecting portions. The parts 3a and 3b are connected to each core 3a, 3b, 4a and 4b via spacers 5a and 5b so as to form an annular shape with an adhesive or the like.

  The coil main body 1 is the same as that of the first embodiment, and includes a wire and a self-bonding layer formed on the surface of the wire. The coil body 1 is an edgewise coil whose wire is a flat wire. The self-bonding layer is made of resin as in the first embodiment. As the resin for the self-bonding layer, those used in conventional self-bonding electric wires can be used. For example, a fusion film composed of an epoxy resin main agent and a curing agent is in a semi-cured state. Things can be used. In addition, although the coil main body 1 is an edgewise coil in which the wire is a flat wire in the present embodiment, it is only necessary that members other than the coil main body 1 can be bonded between the wires by the self-bonding layer. It is not limited to this embodiment. For example, the wire may be a round wire having a round cross section.

  The coil body 1 includes a pair of left and right winding portions 11a and 11b, lead portions 12a and 12b protruding from the first ends of the winding portions 11a and 11b, and winding portions 11a and 11b. A connecting portion 13 provided between the second end portions is provided. The lead portions 12 a and 12 b are end portions of the wire material of the coil body 1. In the present embodiment, the lead-out portions 12a and 12b and the connection portion 13 are formed integrally with the winding portions 11a and 11b by bending one rectangular wire, but the two cylindrical windings are formed. Even if the lead portions 12a and 11b and the connection portion 13 are provided by separately forming the portions 11a and 11b and joining short lead wires separately prepared to these winding portions 11a and 11b by a method such as welding. good.

  The resin member 6 is bonded to the coil body 1 and fixed to the coil body 1. That is, the self-bonding layer of the coil body 1 is bonded to the surface of the resin member 6, and the resin member 6 is fixed to the wire by the self-bonding layer.

  This resin member 6 is formed of resin. The resin may be any resin that has higher heat resistance than the adhesion to the coil body 1 and the adhesion temperature of the self-bonding layer. For example, epoxy resin, unsaturated polyester resin, urethane resin, BMC (Bulk) Molding Compound), PPS (Polyphenylene Sulfide), PBT (Polybutylene Tephthalate), and the like. Moreover, when the resin of the self-bonding layer is an epoxy resin, PPS (product name: FZ-840-D1) manufactured by DIC is preferable. This is because the adhesiveness to the epoxy resin is high.

  The resin member 6 is formed so as to cover the outer periphery of the annular core, and forms an annular shape as a whole following the shape of the annular core. Therefore, the resin member 6 includes a pair of linear straight portions and a connecting portion that connects them. Specifically, as shown in FIG. 13, the resin member 6 is divided into two, and a substantially U-shaped first resin member 60 a and a substantially C-shaped second resin member 60 b are separately provided. It is comprised by shape | molding and mutually abutting the edge part. The reason why the first resin member 60a and the second resin member 60b are separately formed is to accommodate the block-like leg portions 4a and 4b and to fit the coil body 1 therein.

  The first resin member 60a includes a pair of cylindrical straight portions 601a and 601b, a connecting portion 602 that connects these straight portions 601a and 601b, an end portion 603 that contacts the end surface of the coil body 1 of the connecting portion 602, Positioning portions 604a and 604b provided in the connecting portion 602 and fixing portions 605a and 605b provided at both ends of the connecting portion 602 are provided. The second resin member 60b includes a pair of cylindrical straight portions 611a and 611b, a connecting portion 612 that connects these straight portions 611a and 611b, and fixed portions 613a and 613b provided at both ends of the connecting portion 612. Is provided.

  U-shaped yoke portions 3 a and 3 b are embedded in the connection portions 602 and 612. The straight portions 601a, 601b, 611a, and 611b are also referred to as bobbins, and the winding portions 11a and 11b are attached thereto. Inside the straight portions 601a, 601b, 611a, 611b, block-like leg portions 4a, 4b are arranged by alternately laminating spacers 5a, 5b. However, the spacers 5a and 5b are not necessarily provided. Winding portions 11a and 11b of the coil body 1 are mounted on the outer periphery of the straight portions 601a, 601b, 611a and 611b.

  An end 603 of the connecting portion 602 is provided at the boundary between the connecting portion 602 and the straight portion 601a. In other words, the first resin member 60 a has a substantially square shape, and the surface where the straight portions 601 a and 601 b are connected to the connecting portion 602 is the end portion 603. The end surface of the coil body 1 is bonded to the end portion 603. That is, the coil body 1 is bonded to the first resin member 60a by the self-bonding layer on the end surface of the coil body 1.

  As a method for adhering the end surface of the coil body 1 to the end portion 603, for example, the straight portions 601a and 601b are fitted into the air core portions of the winding portions 11a and 11b, and the heating is performed at 170 ° C. to 200 ° C. The self-bonding layer is melted in a state where the end surface of the coil body 1 is pressed against the end portion 603 of the first resin member 60a, and is solidified in a state of being bonded to each other. At this time, the coil body 1 may be pressed using a pressure jig so as not to adhere to the self-bonding layer, but the coil body 1 may be pressed using the second resin member 60b as the pressure jig. You may press. In other words, the coil body 1 is pressed by the second resin member 60b, the self-bonding layer on one end surface of the coil body 1 is adhered to the end 603 of the first resin member 60a, and the second resin member 60b. A self-bonding layer on the other end surface of the coil body 1 may be bonded to the connecting portion 612.

  The positioning portions 604a and 604b are provided on the outer surface of the connecting portion 602 of the first resin member 60a. In the present embodiment, the positioning portions 604a and 604b have a pair of protrusions protruding from the outer surface of the connecting portion 602. The pair of protrusions protrude from the connecting portion 602 in a substantially arrow shape, and are provided slightly narrower than the thickness of the wire of the coil body 1 so that the tips of the protrusions face each other. Drawers 12a and 12b are inserted between the pair of protrusions. That is, the self-bonding layers of the lead portions 12a and 12b are bonded to the protrusions, and the lead portions 12a and 12b are fixed so as to be positioned by the positioning portions 604a and 604b. Note that the self-bonding layer is desirably bonded to both of the pair of protrusions, but may be bonded to only one protrusion.

  Further, as shown in FIG. 11, each protrusion has an arrow shape extending in a trifurcated manner from the tip portion bonded to the self-bonding layer of the lead portions 12a and 12b, so that an external force applied to the lead portions 12a and 12b. Are respectively distributed on the trident leg.

  The fixing parts 605a, 605b, 613a, 613a are used for fixing the reactor to a case (not shown), and the reactors are bolt insertion holes 606a, 606b, 614a of the fixing parts 605a, 605b, 613a, 613a, Bolts are fastened to 614a via nuts 608a, 608b, 615a, 615b.

  The terminal block 110 supports the bus bars 111a and 111b connected to the lead portions 12a and 12b of the coil body 1. The terminal block 110 is provided with mounting portions 110a and 110b for fixing to the first resin member 60a. The receiving portions 607a and 607b provided in the first resin member 60a are aligned with the screw insertion holes, and the screw N1 is attached. The terminal block 110 is fixed to the first resin member 60a by the nut N2.

  Bus bars 111a and 111b have their center portions embedded in terminal block 110 by a resin molding method. One ends 112a and 112b of the bus bars 111a and 111b stand up toward the lead portions 12a and 12b, and are welded to the wire rods exposed by peeling off the self-bonding layers of the lead portions 12a and 12b. The flat plates 113a and 113b at the other end are provided with screw insertion holes 114a and 114b, and are connected to wiring of an external device such as an external power source by inserting and fastening screws into these holes. When power is supplied from an external power source, a current flows through the coil body 1 to generate a magnetic flux penetrating the winding portions 11a and 11b, and an annular closed magnetic circuit is formed in the annular core.

(2) Effect In this embodiment, the coil includes a coil body 1 including a wire, a self-bonding layer formed on the surface of the wire, and a resin member 6 fixed to the wire. Therefore, the wire is bonded and fixed to the resin member 6 by the self-bonding layer. Thereby, a core etc. can be combined with the coil main body 1, and manufacture of electronic components, such as a reactor, can be made easy.

  In particular, according to this embodiment, the following problems can be solved. That is, generally, the tip of the coil used for the reactor has the self-bonding layer peeled off to expose the wire, and the exposed tip of the wire is welded and fixed to the bus bar for connection to an external device. However, during use of the reactor, external force due to vibration of the reactor itself or external equipment is applied to the welded portion between the coil tip and the bus bar, and the connection between the coil tip and the bus bar may be physically disconnected.

  The reactor of this embodiment is a reactor provided with the core, the coil main body 1, and the resin member 6 fixed with respect to the wire of the coil main body 1, Comprising: A core is embedded inside the 1st resin member 60a. Positioning portions 604a and 604b for positioning the lead portions 12a and 12b, which are ends of the coil body 1, are provided on the surface of the first resin member 60a in which the core is embedded. The positioning portions 604a and 604b The self-bonding layers of the lead portions 12a and 12b, which are the end portions of the wire, are bonded to fix the coil body 1 to the first resin member 60a. In particular, the positioning portions 604a and 604b are a pair of protrusions protruding from the surface of the first resin member 60a. The ends of the wire material of the coil body 1 are sandwiched between the pair of protrusions, and the self-bonding layer protrudes. It was made to adhere to.

  As a result, the drawer portions 12a and 12b are fixed to the first resin member 60a by the positioning portions 604a and 604b. Therefore, the reactor or the like is connected to the connection portion between the drawer portions 12a and 12b and the ends 112a and 112b of the bus bars 111a and 111b. In addition, it is possible to obtain a reactor with improved durability by making it difficult to apply an external force due to vibration of an external device or the like. That is, since the self-bonding layer of the coil body 1 is adhered to the protrusions as well as sandwiching only one protrusion, the lead-out portions 12a and 12b are more firmly fixed, and stress due to reactor vibration or the like is applied to the bus bar. Propagation to the welded portion with 111a and 111b can be suppressed.

  The adhesion of the lead portions 12a and 12b by the self-bonding layer is particularly effective when the coil body 1 is not fixed to the case that houses the reactor. That is, when the coil main body 1 is not fixed to the case, there is a gap between the bottom surface of the reactor and the case, the coil main body 1 vibrates during use of the reactor, and the lead wire 12a at the tip portion of the wire rod. , 12b and the bus bar 111a, 111b are stressed and the durability is deteriorated, but since the lead portions 12a, 12b are fixed to the first resin member 60a, the stress applied to the welded portion is reduced. And durability can be improved.

  Further, the end surface of the coil body 1 is bonded to the first resin member 60 by the self-bonding layer of the end surface portion. This also enables the coil body 1 to be fixed to the first resin member 60a. Therefore, propagation of stress due to vibration of the coil body 1 or the like to the welded portion with the bus bars 111a and 111b can be suppressed. In addition, since the end surface of the coil body 1 is directly bonded to the first resin member 60, it is possible to prevent the self-bonding layer from being attached to the pressurization mold and to the first resin member 60 of the coil body 1. Separate mounting work is not required, improving productivity.

6). Other Embodiments The present invention is not limited to the above-described embodiments, and includes other embodiments described below.

(1) In the illustrated embodiment, one resin member is attached to both ends of a pair of left and right coil bodies, but the number of coil bodies to which the resin member is attached depends on the type of electronic component produced by the edgewise coil. 1 or 3 or more.

(2) The flat wire used in the present invention is not limited to a rectangular cross section. Of course, the four corners of the cross section are chamfered in an arc shape or a taper shape, and those in which protrusions are formed on the inner peripheral side or the outer peripheral side of the flat wire surface can be used. For example, if a rectangular wire having protrusions formed on the entire inner periphery is used, the heat radiation area can be increased due to the high adhesive strength and the gap between the rectangular wires. On the other hand, if the protrusions are formed in the entire outer periphery, it is possible to reduce high adhesion strength and the risk of foreign matter mixing between the rectangular wires.

(3) In the illustrated embodiment, since the coil body is formed by winding a rectangular wire into a quadrangular shape, the four corners of the rectangular shape are bent portions, and the protruding portion protruding from the surface of the rectangular wire is a rectangular shape. It is formed in a substantially dot shape at the four corners. When the coil body is formed by winding a rectangular wire into a circle, a protrusion is formed in the entire inner circumference of the coil. Therefore, when a ridge is formed in the entire inner circumference of the rectangular wire section of (2) above. Similarly, it is possible to increase the heat radiation area due to the high adhesive strength and the gap between the rectangular wires.

(4) “Mounting” in the present invention is not limited to mounting so as to cover the end of the coil body as shown. Any structure that can be fixed or locked so as not to be detached from the end of the coil body at the time of pressurization may be used. For example, a plate-shaped resin member is temporarily fixed with a tape or the like to a portion where a pressing member such as a mold comes into contact, and heated and pressurized, and the coil body and the resin member are fixed by a flat wire self-bonding layer. You can also

(5) When the coil body is bonded to the rectangular wire adjacent to the inner periphery of the bent portion by a protruding portion from the surface of the rectangular wire by the self-bonding layer, the entire inner periphery may be used, or the coil body may be wound in a rectangular shape. It may be fused with the adjacent rectangular wire at some points such as the corners of the four corners of the rectangular wire. Further, when a rectangular wire having a cross-sectional shape protruding from the outer peripheral side of the coil is used, it may be fused to the rectangular wire adjacent to the entire outer periphery of the coil or a part of the outer periphery.

(6) When a protrusion is formed on the surface of a flat wire, the adjacent flat wires are fused together in a state in which a part of the protrusion is crushed or the flat wire surface is flattened until there is no protrusion. You can also It is also possible to fuse flat wires having flat surfaces with no protrusions, either partially or entirely.

(7) In the fifth embodiment, the positioning portions 604a and 604b are provided only on the first resin member 60a side. However, the present invention is not limited to this and may be provided on the connecting portion 612 on the second resin member 60b side. . Moreover, when the drawer part of the coil main body 1 is pulled out to each of the connection parts 602 and 612, a positioning part may be provided in both of the connection parts 602 and 612 corresponding to each.

(8) In the fifth embodiment, among the both end faces of the coil body 1, only the end portion 603 of the connecting portion 602 that is one end surface is bonded, but the other connecting portions 612 are attached in the winding direction of the coil body 1. The self-bonding layer of the coil main body 1 may be adhered to the end surfaces of the other connecting portions 612 by pressing against each other.

(9) In the fifth embodiment, the tips of the protrusions facing each other in the positioning portions 604a and 604b are pointed, but the portions of the protrusions facing each other may be flat. Thereby, since the adhesion area of the self-bonding layer is increased and the self-bonding layer can be more firmly fixed, the stress on the welded portion with the bus bars 111a and 111b can be further reduced.

(10) In the fifth embodiment, the positioning portions 604a and 604b are configured by a pair of protrusions protruding from the outer surface of the connecting portion 602, but a part of the surface of the resin member 6 is recessed in a groove shape, The lead portions 12a and 12b may be fitted into these portions, and the self-bonding layers of the lead portions 12a and 12b may be bonded. Further, the positioning portions 604a and 604b are protrusions having an opening, and the lead portions 12a and 12b of the coil body 1 may be inserted into the opening and the self-bonding layer may be bonded to the inner periphery of the opening.

(11) In the fifth embodiment, the surface of the resin member 6 may be subjected to plasma treatment, corona treatment, UV treatment, or blast treatment in order to improve the adhesion of the surface of the resin member 6 to be adhered with the self-bonding layer. .

(12) In the first to fifth embodiments, the self-bonding layer on the inner peripheral side of the winding portions 11 a and 11 b of the coil body 1 may be adhered to the surface of the resin member 6. Thereby, the coil main body 1 can be firmly fixed by the resin member 6.

(13) In 1st thru | or 5th embodiment, in order to protect a reactor from foreign materials, such as metal powder, you may provide protective covers made from resin, such as PPS. In this case, the coil body 1 may be pressed by the protective cover, and the bottom surface of the protective cover may be adhered to the self-bonding layer of the coil body 1. Further, the protective cover and the coil body 1 may be bonded and fixed so as to press down the self-bonding layers of the lead portions 12a and 12b with the protective cover.

(14) When the reactor is accommodated in the case and the coil main body 1 is not fixed by the filler, the spacer may be fixed to the bottom surface of the coil main body 1 by bonding with a self-bonding layer. That is, the spacer is a resin member such as PPS having a height corresponding to the distance between the bottom surface of the coil body 1 and the bottom surface of the case, and is bonded by the self-bonding layer on the bottom surface of the coil body 1. When the reactor is bolted to the case, the spacer fits between the bottom surface of the coil body 1 and the bottom surface of the case, so that the coil body 1 can be fixed in position.

(15) In the first to fifth embodiments, the self-bonding layer of the coil body 1 is bonded to the resin member used for the reactor, but the present invention is not limited to this. That is, the self-bonding layer of the coil body 1 may be bonded to a resin member other than the resin member used for the reactor. For example, when the resin member is provided in the installation location of the reactor, the reactor may be fixed by adhering the self-bonding layer of the coil body 1 to the resin member. An example of the location of the reactor is a circuit board, and the self-bonding layer of the coil body 1 is bonded to a resin substrate or a resin member on the circuit board.

DESCRIPTION OF SYMBOLS 1 ... Coil main body 11a, 11b ... Winding part 12a, 12b ... Drawer part 13 ... Connection part 2a, 2b ... Coil side resin member 21 ... End face plate 22, 22a, 22b ... Edge plate 23a, 23b ... Opening part 24a, 24b ... notches 25 ... brackets 26 ... screw holes 27 ... recesses 3a, 3b ... yoke parts 4a, 4b ... legs 5a, 5b ... spacers 6a, 6b ... core side resin members 61a, 61b ... bobbins 62 ... pins 63a, 63b ... guides 64 ... Brackets 65, 66a, 66b ... Screw holes 67 ... Openings 68a, 68b ... Pins 7 ... Screws 8 ... Fixing brackets 81a, 81b ... Screw holes 82a, 82b, 93a, 93b ... Locking holes 9 ... Cover R ... Bending Part L ... Flat wire surface W ... Protruding part 6 ... Resin member 60a ... First resin member 601a, 601b ... Linear part 602 ... Connection part 603 ... End part 604a, 604a ... Position Female portions 605a, 605b ... fixing portions 606a, 606b ... bolt insertion holes 607a, 607a ... receiving portions 608a, 608b ... nuts 60b ... second resin members 611a, 611b ... linear portions 612 ... connecting portions 613a, 613b ... fixing portions 614a , 614b ... bolt insertion holes 615a, 615b ... nuts 110 ... terminal blocks 110a, 110b ... mounting portions 111a, 111b ... bus bars 112a, 112b ... one end 113a, 113b ... flat plates 114a, 114b ... screw insertion holes N1 ... screws N2 ... nut

Claims (17)

A coil body comprising a wire and a self-bonding layer formed on the surface of the wire;
A resin member fixed to the wire,
A coil comprising
The wire is bonded and fixed to the resin member by the self-bonding layer;
Coil characterized by The coil body is an edgewise coil around which a rectangular wire as the wire is wound,
The resin member is attached to an axial end of the coil body,
The coil body is pressed from the axial direction of the coil body through the resin member in a state where the resin member is mounted,
The rectangular wire surface self-bonding layer is heated and melted, and adjacent portions of the wound rectangular wire are bonded to each other;
The coil according to claim 1.   The coil according to claim 2, wherein the resin members are respectively attached to both ends of the coil body.   A protrusion protruding from the flat wire surface is formed on at least a part of the coil body, and a portion of the protrusion is bonded to an adjacent portion of the flat wire by a self-bonding layer. The coil according to claim 2 or 3. At least a part of the coil body is formed with a protruding portion protruding from the flat wire surface,
After the winding of the rectangular wire, the protruding portion is crushed by being pressurized from the axial direction of the coil body, and adjacent portions of the rectangular wire are bonded together by a self-bonding layer. The coil according to claim 2 or 3. The coil body has a protruding portion protruding from the surface of the rectangular wire on at least a part of the inner periphery of the bent portion,
After the winding of the rectangular wire, the protrusion is crushed by being pressed from the axial direction of the coil body, and adjacent portions of the rectangular wire are bonded by a self-bonding layer. The coil according to claim 2 or 3. The coil body is formed by winding a flat wire with a flat surface so that the flat surfaces face each other,
The coil according to claim 2 or 3, wherein adjacent portions of the flat wire are bonded to each other by at least a part of a flat surface by a self-bonding layer.   The coil according to any one of claims 2 to 7, wherein the resin member has a through-hole portion of a connection terminal protruding from an end portion of the coil body.   The coil according to any one of claims 2 to 8, wherein the resin member has a fixing portion of a core to be inserted into the coil body. A reactor comprising a core and the coil according to claim 1,
The core is embedded in the resin member;
A positioning portion for positioning the end of the coil body is provided on the surface of the resin member in which the core is embedded;
Reactor characterized by. A self-bonding layer at an end of the wire rod is bonded to the positioning portion, and the wire rod of the coil body is fixed to the resin member;
The reactor according to claim 10. The positioning portion is a pair of protrusions protruding from the surface of the resin member,
An end portion of the wire body of the coil body is sandwiched between the pair of protrusions, and the self-bonding layer is bonded to the protrusions;
The reactor according to claim 11. A reactor comprising a core and the coil according to claim 1,
The core is embedded in the resin member;
The end surface of the coil body is bonded to the resin member by the self-bonding layer;
Reactor characterized by. A coil manufacturing method comprising a wire body, a coil body including a self-bonding layer formed on a surface of the wire, and a resin member fixed to the wire,
Pressurizing the coil body to the resin member, heating and melting the self-bonding layer, and bonding and fixing the wire to the resin member;
A method for manufacturing a coil, characterized in that The coil is an edgewise coil in which the wire is a flat wire,
The resin member is attached to the axial end of the coil body,
With the resin member mounted, pressurize from the axial direction of the coil body through the resin member,
The coil manufacturing method according to claim 14, wherein the self-bonding layer on the surface of the rectangular wire is heated and melted, and adjacent rectangular wires are bonded to each other. A coil body is formed by winding a rectangular wire having a self-bonding layer formed on the surface,
Forming a protrusion protruding from the surface of the rectangular wire on at least a part of the coil body;
The coil manufacturing method according to claim 15, wherein the protruding portion is bonded to a portion of a rectangular wire adjacent to the protruding portion by a self-bonding layer. A coil body is formed by winding a rectangular wire having a self-bonding layer formed on the surface,
Forming a protrusion protruding from the surface of the rectangular wire on at least a part of the coil body;
By pressing the coil body from the axial direction of the coil after winding the rectangular wire, the protrusion is crushed,
The method for manufacturing a coil according to claim 15, wherein the adjacent portions of the flat wire are bonded to each other by a self-bonding layer by a part or all of the surface thereof.

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