JP2017115240A - Insulation-coated wire component manufacturing method and electrodeposition jig - Google Patents

Abstract

PROBLEM TO BE SOLVED: To decrease residual of air bubbles within an insulation coating.SOLUTION: The insulation-coated wire component manufacturing method includes: an electrodeposition step which attaches a coating material by electrodeposition to an area between both ends 2A, excluding both ends 2A, of a wire component 1A to be insulation-coated; and a baking step which bakes the coating material attached to the wire component by heating the wire component 1A after electrodeposition to form an insulation coating on the wire component 1A. In the baking step, both ends 2A of the wire component 1A are placed on a heater 39 to heat the wire component 1A with heat conduction from the heater 39 to the wire component 1A.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method for manufacturing an insulation-coated electric wire part and an electrodeposition coating jig by attaching an insulating paint to an electric wire part processed into a part shape such as a coil by an electrodeposition coating technique and baking it.

  Insulated coated electric wires such as so-called enameled wires are manufactured by applying insulating paint (varnish) based on insulating resin to the electric wire and baking it. Electrodeposition coating technology attracts attention as a technique for applying the insulating paint. Yes. In addition, when the insulation-coated electric wire is a coil used for a motor, a transformer, or the like, since the insulation coating may be cracked when processed into the coil part shape after insulating coating in the state of the electric wire, Attempts have been made to insulate and coat bare wires that have not been insulatively coated into coils.

  For example, Patent Document 1 discloses electrodeposition coating of a work obtained by processing a flat wire into an electromagnetic coil shape for a motor (edgewise winding). In Patent Document 1, both end portions of a workpiece are held by a chuck and held in a suspended state, and a portion below the gripped portion is immersed in an electrodeposition liquid while being conveyed in the suspended state. And it is described that after coating, an insulating coating is formed by drying or curing.

  Also, in Patent Document 2, both ends of the coil are held by the hanger and held in a suspended state, and the lower part from the gripped part is dipped in the electrodeposition liquid, and then painted. It is described that the coating is cured by being placed inside and cooled after being heated using infrared rays or hot air. Further, it is described that bubbles are likely to be generated on the surface when the film thickness of the insulating film is increased.

  On the other hand, Patent Document 3 discloses a technique for removing bubbles generated in the coating, and the work piece is taken out from the electrodeposition solution a plurality of times during the electrodeposition coating process to remove bubbles adhering to the work piece. However, it is described that electrodeposition is applied. According to Patent Document 3, if the continuous immersion time in which the workpiece is immersed in the electrodeposition liquid without taking out the workpiece is increased along with the elapsed time from the start of the electrodeposition coating process, bubbles can be efficiently removed. It is said that.

JP 2012-117133 A JP 2012-224924 A JP 2012-180585 A

  By the way, as described in Patent Document 2, bubbles are likely to be generated in a portion where the coating is thick. For this reason, when electrodepositing a linear electric wire before being processed into a coil or the like, it is easy to form a coating with a uniform thickness. In the case of electrodeposition coating after processing into a form, since it has a shape having a bent portion or the like, the thickness of the film tends to vary, and the drying and baking tends to be nonuniform. For this reason, there exists a problem that a bubble tends to remain.

  The present invention has been made in view of such circumstances, and a method for manufacturing an insulation-coated electric wire component capable of reducing the remaining of bubbles in the insulation coating, and an electrodeposition coating jig suitable for use in the manufacture thereof. The purpose is to provide.

  The method for manufacturing an insulation-coated electric wire component according to the present invention includes an electrodeposition coating process in which a paint is adhered to a portion between both ends except for both ends of an electric wire component to be insulated, and after electrodeposition coating. A baking step of forming an insulating coating on the electric wire component by heating the electric wire component and baking the paint adhering to the electric wire component, and in the baking step, the both end portions of the electric wire component on the heater. At least one of the end portions is placed, and the electric wire component is heated by heat conduction from the heater to the electric wire component.

  Since the electric wire component is a good electric conductor, it has excellent thermal conductivity, and by placing the end of the electric wire component on the heater in the baking process, the heat of the heater moves from the end to the length of the electric wire component. Conducts and heats wire components. For this reason, an electric wire component will be heated from the inside, and the coating material adhering to the circumference | surroundings of an electric wire component will also be heated from the inner side which is contacting the electric wire component, and will be hardened | cured from the inner side toward the outer side. Therefore, even if bubbles remain in the paint adhering to the electric wire parts, when the paint hardens from the inside to the outside, the bubbles are pushed from the inside to the outside by the hardening layer that gradually thickens. Easily coming off the outer surface.

  In the method of manufacturing an insulation-coated electric wire component according to the present invention, in the electrodeposition coating step, the paint is adhered in a state where the one end of the electric wire component is held by a clamp made of a heat conductive material, and in the baking step, The clamp is placed on the heater, and heat is transferred to the electric wire component through the clamp.

  By forming the clamp that grips the end of the wire component with a heat conductive material, the wire component can be immersed in an electrodeposition bath filled with insulating paint by gripping the clamp in the electrodeposition coating process. After the paint is applied, by placing the clamp on the heater, the heat of the heater can be transferred from the clamp to the electric wire component to heat the electric wire component, making it easy to handle a series of processes. can do. When both ends of the electric wire component are placed on the heater and heated, both the clamps that hold each end may be made of a heat conductive material.

In the method for manufacturing an insulation-coated electric wire part of the present invention, in the baking step, the electric wire part may be further covered with a heat insulating cover.
Heat dissipation from the electric wire component can be suppressed by the heat insulating cover, and the electric wire component can be sufficiently heated to form a good insulating coating.

In the electrodeposition coating jig according to the present invention, at least a pair of clamps for holding both ends of an electric wire part to be insulated is fixed on a base, and at least one of the pair of clamps and the base Is formed of a heat conductive material.
Electrodeposition coating is performed with the electric wire parts held by the clamp on the base, and the base is placed on the heater in this holding state, so that the heat of the heater is transmitted to the base, and the electric wire is transferred from the base through the clamp. It can be transmitted to parts and can be used in both electrodeposition coating and baking processes.

In the electrodeposition coating jig of the present invention, the base may be formed in a flat plate shape, and an opening penetrating in the thickness direction of the base plate may be formed between the pair of clamps.
Heat of the heater is transferred to the electric wire parts by heat transfer via the base and clamp, but when the base is placed on the heater, the heat of the heater is also transferred to the electric wire parts by radiation from the opening. The electric wire component can be effectively heated by the action of both the heat conduction and the heat radiation from the outside of the electric wire component.

  According to the present invention, since the heat of the heater is conducted in the length direction of the electric wire component from the end portion of the electric wire component to which the insulating paint is adhered, the electric wire component is heated, so that the insulating paint is directed from the inside to the outside. It is possible to cure, thereby making it easier for bubbles to escape from the outer surface, and to reduce the remaining bubbles and form a good insulating film.

It is a perspective view which shows the state which hold | maintained the electric wire components in the jig for electrodeposition coating used for one Embodiment of the manufacturing method of this invention, and was mounted on the heater. It is a perspective view which shows the jig | tool for electrodeposition coating shown in FIG. It is sectional drawing which shows typically the example of the electrodeposition coating in the manufacturing method of this embodiment. It is a perspective view which shows typically the example of the baking apparatus used for the manufacturing method of this embodiment. It is a perspective view which shows the example of the electric wire components in which insulation coating is given by the manufacturing method of this embodiment. It is a perspective view which shows the example of the coil components by which an insulating film is given by one Embodiment of the manufacturing method of this invention. It is a perspective view which shows the state which hold | maintained the coil components shown in FIG. 6 to the electrodeposition coating jig used for the manufacturing method of this invention.

Hereinafter, embodiments of the present invention will be described.
The insulation-coated electric wire component in this embodiment is a coil segment used for a stator of an electric motor or a generator. As shown in FIG. 5, the electric wire component 1A has a rectangular conductor in an inverted U shape (or an arch shape). It is formed by bending, and the central portion 3A is covered with an insulating coating except for both end portions 2A. In this insulated coated electric wire component (coil segment), both end portions 2A where the flat conductor is exposed are coupled to the stator core.

  This insulation-coated electric wire component has a central portion except for a forming step of processing a flat conductor into the shape of the electric wire component 1A, a cleaning step of cleaning the processed electric wire component 1A, and both ends 2A of the cleaned electric wire component 1A. It is manufactured through an electrodeposition coating process in which an insulating paint is attached to 3A by an electrodeposition coating technique, and a baking process in which the wire part 1A is heated and the attached insulating paint is dried and baked.

  In the forming step, the rectangular conductor is processed into a wire part 1A as shown in FIG. 5 by ordinary press forming or the like. In the example shown in FIG. 5, the electric wire component 1 </ b> A is formed in an inverted U shape as a whole by bending a flat conductor, and is a central portion that spans between the end portions 2 </ b> A when the end portion 2 </ b> A is directed downward. (Head) 3A is bent and formed in the thickness direction of the flat conductor, and therefore both end portions 2A are shifted in the thickness direction of electric wire component 1A.

In the electrodeposition coating process, an electrodeposition coating jig 11A shown in FIG. 2 is used.
This electrodeposition coating jig 11A is a jig for electrodeposition coating on the portion between the two end portions 2A (the hatched portion in FIG. 5) except for the two end portions 2A of the electric wire component 1A. The base 12 is composed of a plurality of pairs of clamps 13 fixed to one side of the base 12. Each clamp 13 grips the end portion 2A of the electric wire component 1A. In the illustrated example, the clamp 13 is fixed to the base 12 and the movable side is fixed to the fixed clamp member 14 with screws 15. A clamp member 16 is provided, and a slot portion 17 is formed between the opposing portions of the clamp members 14 and 16 to hold the end portion 2A of the electric wire component 1A in an inserted state by fastening the clamp members 14 and 16. Has been. The slot portion 17 is provided with a spring piece 18 that elastically contacts the end portion 2A of the inserted electric wire component 1A.

In this case, the clamps 13 are fixed on the base 12 so as to form a plurality of rows, and are arranged in pairs between adjacent rows, as indicated by the white arrows in FIG. By inserting and gripping the end portions 2A of the electric wire components 1A in the slot portions 17 of the pair of clamps 13 respectively, the electric wire components 1A are bridged between the rows of the clamps 13 perpendicular to the base 12. It is the structure held in. Since the pair of clamps 13 are arranged side by side, the electric wire parts 1A are also arranged in a row at the same interval and in the same posture (see FIG. 1).
The base 12 is formed with an opening 19 along the thickness direction so as to remove a portion between the pair of clamps 13.

In the illustrated example, three wire parts 1A are arranged in a row, and three rows are arranged in total. And since the opening part 19 is each formed between the clamps 13 which make a pair in each row | line | column, each electric wire component 1A is arrange | positioned so that the upper part of this opening part 19 may be straddled.
The base 12 and the clamp 13 are made of a material having good electrical and thermal conductivity, for example, a metal such as aluminum or copper.
The clamp 13 is not limited to the type in which the movable side clamp member 16 is fixed by the illustrated screw 15 but may be of the type in which the movable side clamp member 16 is biased using a spring or the like.

Next, an electrodeposition coating process for attaching an insulating paint to the electric wire component 1A using such an electrodeposition coating jig 11A will be described.
Both ends 2A of the electric wire component 1A processed by the forming process are held by the clamps 13 of the electrodeposition coating jig 11A, and the electric wire component 1A is held in a vertically standing state on the base 12. Then, the base 12 of the electrodeposition coating jig 11A holding the electric wire component 1A is supported by a hanger (not shown), and the electric wire component 1A is suspended. That is, the wire component 1A is supported in a state in which the end 2A gripped by the clamp 13 faces upward and the central portion 3A disposed between the ends 2A faces downward. In addition, wiring (both not shown) is connected to the base 12 by an alligator clip or the like. The hanger is formed of an insulator.

In this suspended state, as shown in FIG. 3, the central portion 3 </ b> A exposed from the clamp 13 except for the end 2 </ b> A gripped by the clamp 13 in the electrodeposition tank 22 filled with the insulating paint 21. Is immersed in the electrodeposition tank 22, and an electric current is passed from the DC power source 24 between the base 12 and the electrode 23 in the electrodeposition tank 22 to perform electrodeposition coating.
The insulating paint 21 stored in the electrodeposition tank 22 is an insulating paint (varnish) based on polyurethane resin, polyester resin, polyesterimide resin, polyamideimide resin, polyimide resin, or the like, and is added with a curing agent or the like. The

  After being immersed in the electrodeposition tank 22 for a predetermined time, the electric wire part 1A is pulled up from the electrodeposition tank 22, and the paint (insulating paint 21) attached to the electric wire part 1A is baked.

  And in the baking process, the baking apparatus 31 shown in FIG. 4 is used. In this baking apparatus 31, a receiving station 34 is installed at an entrance of a passage 33 surrounded by a tunnel-shaped heat insulating cover 32, and a drying station 35, a baking station 36, and a cooling station 37 are sequentially installed inside the heat insulating cover 32. The take-out station 38 is installed at the exit of the passage 33. The drying station 35 and the baking station 36 are each provided with a heater 39, and the cooling station 37 is provided with a blower (not shown) for supplying cold air. Each of the stations 34 to 38 is partitioned by a shutter. Transfer between each station 34-38 is performed by moving the electric wire component 1A intermittently, for example by intermittent conveyance means (not shown), such as a walking beam.

The heater 39 installed in the drying station 35 and the baking station 36 is formed in a plate shape, is disposed horizontally on the passage 33, and its upper surface is a heat radiating surface 39a.
Then, the base 12 of the electrodeposition coating jig 11A is placed on the receiving station 34 with the electric wire component 1A facing upward, and is sequentially placed on the heaters 39 of the drying station 35 and the baking station 36 by intermittent conveying means. Transport.
As shown in FIG. 1, when the base 12 holding the electric wire component 1A is placed on the heat radiation surface 39a of the heater 39, the base 12 and the clamp 13 are made of a material (aluminum, copper, etc.) having good heat conduction. Since it is formed, the heat of the heater 39 is quickly transmitted from the heat radiating surface 39a, is conducted inside, is conducted from the clamp 13 to the end 2A of the wire component 1A, and is conducted in the length direction in the wire component 1A. Since this electric wire component 1A is a good electrical conductor and excellent in heat conduction, it is quickly heated.

  In this way, in the drying station 35, the electric wire component 1A is heated to, for example, 150 ° C. by the drying heater 39 to dry the insulating paint, and in the baking station 36, the electric wire component 1A is, for example, 200 by the baking heater 39. The paint is baked by heating to ˜300 ° C. Finally, after cooling at the cooling station 37, the product is taken out from the take-out station 38 and removed from the clamp 13 of the electrodeposition coating jig 11 </ b> A.

As described above, in the electrodeposition coating of this embodiment, the electrodeposition coating jig 11A is electrodeposited with the wire component 1A held thereon, and further subjected to a baking process, whereby the electrodeposition coating process is followed by the baking process. It is possible to facilitate the handling of the electric wire component 1A during the series of steps up to here.
Further, in the baking process, the heat of the heater 39 is conducted in the length direction from the end 2A of the electric wire component 1A to heat the electric wire component 1A from the inside, so that the paint adhered to the electric wire component 1A is also directed from the inside to the outside. Even if air bubbles remain in the paint adhering to the electric wire component 1A, the air bubbles are also pushed from the inside to the outside by the gradually increasing thickness of the hardened layer, and are easily removed from the outer surface. Therefore, it is possible to reduce the remaining bubbles and form a high-quality insulating film.

Furthermore, in this baking process, since the opening part 19 is formed in the base 12, and the electric wire component 1A is arranged so as to straddle the opening part 19, the radiant heat from the heater 39 in the part facing the opening part 19 is It is transmitted to the component 1A and the wire component 1A can be heated from the outside. Further, heat dissipation is suppressed by the heat insulating cover 32, and the electric wire component 1A can be effectively and uniformly heated.
Even in the case where radiant heat is added in this way, heating from the inside is mainly performed, and the effect of suppressing bubbles is not affected.

In addition, this invention is not limited to the said embodiment, A various change can be added in the range which does not deviate from the meaning of this invention.
In the above embodiment, both ends 2A of the wire component 1A are held by the electrodeposition coating jig 11A, and both the ends 2A are placed on the heater 39. It is also possible to place only one end portion on the heater 39 so that the heat conduction is performed from the one end portion to the entire electric wire component 1A. In that case, the clamp which hold | grips the one edge part should just be comprised with the heat conductive material.

Further, in the above embodiment, as shown in FIG. 5, the case where the insulation covered electric wire part is manufactured by insulatingly covering the electric wire part 1 </ b> A formed by bending a rectangular conductor into an inverted U shape has been described. The applied electric wire component is not limited to the shape shown in FIG. 5, and various types of electric wire components can be adopted.
For example, as shown in FIG. 6, the electric wire component to which the present invention is applied is formed into a flat shape by winding a rectangular wire having a flat cross section in a spiral shape to form a plurality of winding portions 4. A coil with an insulating coating (coil segment) comprising the coil component 1B and having a central portion 3B (a portion shown by hatching in FIG. 6) excluding both end portions 2B can be employed. This coil with an insulating film is used for a stator of an electric motor or a generator, for example.
The components such as a clamp used for the electrodeposition coating jig 11B are the same as those of the electrodeposition coating jig 11A shown in FIGS. 1 and 2, and the first embodiment is shown in FIGS. Elements common to the forms are denoted by the same reference numerals and description thereof is omitted.

  Also in the electrodeposition coating of the coil component 1B, the electrodeposition coating jig 11B shown in FIG. 7 is electrodeposited while holding the coil component 1B, and further subjected to a baking process, so that the electrodeposition coating process is followed by the baking process. The handling of the coil component 1B during the series of steps up to can be facilitated. Further, in the electrodeposition coating jig 11B, the end portions 2B of the coil component 1B are inserted and held in the slot portions 17 of the pair of clamps 13, respectively, so as to be formed between both end portions 2B of the coil component 1B. A plurality of winding portions 4 are spaced apart to be in an extended state, that is, electrodeposition coating can be applied in a linear state without overlapping the winding portions 4 and dry baking can be performed. Also in this electrodeposition coating jig 11B, the baking step conducts heat from the heater 39 in the length direction from the end 2B of the coil component 1B to heat the coil component 1B from the inside, so that the coil component 1B The coating material adhering to the inside will also be cured from the inside to the outside, and even if bubbles remain in the coating material adhering to the coil component 1B, the bubbles gradually move from the inside to the outside due to the gradually thickening layer. It becomes easy to come off from the outer surface when pushed. Therefore, an insulating film having a uniform thickness can be formed around the conducting wire of the coil component 1B, and the remaining of bubbles can be reduced to form a high-quality insulating film.

In order to confirm the effect of the present invention, the following experiment was conducted.
In Examples 1 to 5 and Comparative Examples 1 to 5 in Table 1, a wire part having a shape in which a flat conductor having a thickness of 1 mm and a width of 3 mm is bent with oxygen-free copper to 20 cm as shown in FIG. did. Further, in Examples 6 to 9 in Table 1, a flat conductor having a flat cross section (0.6 mm × 12 mm) as shown in FIG. A coil component in which the part was formed in an oval shape (flat shape with a winding outer diameter of 100 mm × 50 mm) was produced.
A jig for electrodeposition coating of electric wire parts having the configuration shown in FIG. 2 was produced, and the base and the clamp were produced using aluminum. Similarly, an electrodeposition coating jig for coil parts having the structure shown in FIG. 7 was produced, and the base and the clamp were produced using aluminum. Then, after the electrodeposition coating is performed on the electric wire part or the coil part using an insulating paint mainly composed of polyamideimide (PAI) and an insulating paint mainly composed of polyimide (PI) resin, what is described in the embodiment In the same manner as above, an electrodeposition coating jig was placed on the heater, and the electric wire parts were heated by heat conduction.
In Comparative Examples 1 to 5, the electrodeposition-coated electric wire parts were installed in a muffle furnace and heated by radiant heat from the furnace wall.

In all cases, the temperature of the electric wire component was increased to 150 ° C., held at 150 ° C. for 5 minutes to dry, then held at 250 ° C. for 3 minutes, and then cooled after baking. The heating rate was as shown in Table 1, the thickness of the insulating coating after baking was measured, and the remaining state of the bubbles was inspected. When there was a bubble that could be confirmed by visual observation, the bubble was judged as “present”, and when it was not confirmed, it was judged as “absent”.
The results are shown in Table 1.

  As is clear from Table 1, no bubbles remained in the insulating coating in any of the examples. From this result, it can be seen that a high-quality insulating coating without bubbles can be formed by heating from the inside of the electric wire component by heat conduction.

1A: Electric wire component 1B: Coil component (electric wire component)
2A, 2B ... end 3A, 3B ... central part 4 ... winding part 11A, 11B ... electrodeposition coating jig 12 ... base 13 ... clamp 14 ... fixed side clamp member 15 ... screw 16 ... movable side clamp member 17 ... Slot part 18 ... Spring piece 19 ... Opening part 21 ... Insulating paint 22 ... Electrodeposition tank 23 ... Electrode 31 ... Baking device 32 ... Thermal insulation cover 33 ... Passage 34 ... Receiving station 35 ... Drying station,
36 ... Baking station 37 ... Cooling station 38 ... Taking station 39 ... Heater 39a ... Heat radiation surface

Claims (5)

An electrodeposition coating process in which a paint is applied to the portion between the both ends excluding both ends of the electric wire component to be insulated;
A baking step of forming an insulating coating on the wire part by heating the wire part after electrodeposition coating and baking the paint adhering to the wire part;
In the baking step, at least one end of the both ends of the electric wire component is placed on a heater, and the electric wire component is heated by heat conduction from the heater to the electric wire component. A method of manufacturing an insulated wire component. In the electrodeposition coating step, the paint is adhered in a state where the one end of the electric wire component is held by a clamp made of a heat conductive material,
2. The method of manufacturing an insulation-coated wire part according to claim 1, wherein, in the baking step, the clamp is placed on the heater and heat is transferred to the wire part through the clamp.   The method for manufacturing an insulated wire part according to claim 1, wherein the wire part is further covered with a heat insulating cover in the baking step.   At least one pair of clamps for gripping both ends of the electric wire component to be insulated is fixed on the base, and at least one of the pair of clamps and the base are made of a heat conductive material. An electrodeposition coating jig characterized by   5. The electrodeposition coating according to claim 4, wherein the base is formed in a flat plate shape, and an opening penetrating in a thickness direction of the base plate is formed between the pair of clamps. jig.

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