JP2018107242A - Coil and manufacturing method of coil - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a coil superior in insulation property, and a manufacturing method of coil.SOLUTION: A coil in an embodiment is a coil which is constituted of a wound conductive wiring conductor which is molded with resin. The wiring conductor has an element wire 314 as the conductor directly covered with a nonwoven fabric 32.SELECTED DRAWING: Figure 16

Description

  Embodiments described herein relate generally to a coil and a method for manufacturing the coil.

  The coil is formed by winding a conductor such as a litz wire obtained by twisting a plurality of strands, a square wire having a rectangular cross section, or a round wire having a circular cross section. And the circumference | surroundings of a conductor and the outer periphery of a coil are covered with the insulating material in order to ensure electrical insulation.

JP 2000-90747 A

In the case of the above configuration, when the insulation properties of the conductor and the coil are lowered, the performance of the coil is lowered.
Therefore, a coil excellent in insulation and a method for manufacturing the coil are provided.

  The coil of the embodiment is a coil formed by winding a winding conductor in which a conductive conductor is molded with a resin. The winding conductor is surrounded by a nonwoven fabric.

The figure which shows typically the coil which uses the litz wire as the conductor Diagram showing the cross-sectional structure of the coil The figure which shows the state of the middle process of the manufacturing process of the coil The figure which shows the state of the middle process of the manufacturing process of the coil The figure which shows the state of the middle process of the manufacturing process of the coil The figure which shows the state of the middle process of the manufacturing process of the coil The figure which shows the state of the middle process of the manufacturing process of the coil Sectional drawing which shows the state of the process in the middle of the manufacture process of a coil The figure which shows the state of the middle process of the manufacturing process of the coil The figure which shows the cross-sectional structure of the coil which used the square wire as a conductor The figure which shows the state of the middle process of the manufacturing process of the coil The figure which shows the state of the middle process of the manufacturing process of the coil The figure which shows the state of the middle process of the manufacturing process of the coil Sectional drawing which shows the state of the process in the middle of the manufacture process of a coil Diagram showing other conductors The figure which shows the aspect which covers a conductor with a nonwoven fabric typically The figure which shows the aspect which winds the conductor covered with the nonwoven fabric with a tape

  Hereinafter, embodiments will be described with reference to the drawings. In addition, for simplification of explanation, while individually explaining a coil using a litz wire as a conductor, a coil using a square wire as a conductor, and a mode in which the conductor is directly covered with a nonwoven fabric, In the description of the coil used, the method for manufacturing the coil will also be described. In addition, the same code | symbol is attached | subjected to the substantially common site | part.

<Coil using litz wire as conductor>
Hereinafter, a coil using a litz wire as a conductor will be described with reference to FIGS. FIG. 1 is a perspective view illustrating a schematic configuration example of a coil 10 shown as an example of the embodiment, and FIG. 2 is a cross-sectional view illustrating a configuration in a portion A of the coil 10 in FIG. As shown in FIG. 1, the coil 10 is composed of a litz wire 12 that is a winding conductor bundled by twisting thin wires made of, for example, copper.

  The coil 10 is configured such that the litz wire 12 has a hollow in the center and is concentrically formed, for example, an ellipse, and is wound in close contact with a spiral, and the whole is hardened by a resin. A portion A in FIG. 1 is a portion corresponding to a basic unit of the litz wire 12, and FIG. 2 shows a basic configuration of the litz wire 12 constituting the coil 10.

  A litz wire 12 used in the coil 10 is a multi-conductor magnet wire (winding) formed by twisting and bundling a plurality of conductive strands 14 (thin wires) insulated from each other, for example, a plurality of enamel wires having an insulating coating. Conductor). As shown in FIG. 2, the litz wire 12 includes a first unit litz wire 16 formed by twisting a plurality of strands 14.

  Furthermore, the 2nd unit litz wire 18 is comprised by twisting the some 1st unit litz wire 16 together. The litz wire 12 is formed by covering the periphery of the second unit litz wire 18 with a securing band 22 and a surrounding band 24.

  As the tying band 22, for example, a strong aramid fiber tape is used. The tying band 22 has a paper tape shape, and the first unit litz wire 16 or the strand 14 constituting the second unit litz wire 18 is unwound by winding around the second unit litz wire 18. Used to tie up so that there is no.

  As shown in FIG. 4A described later, the lashing band 22 is wound around the second unit litz wire 18 so that a gap G is formed between the lashing bands 22 to be wound. The surrounding band 24 is wound around and covered the second unit litz wire 18 secured by the securing band 22. The encircling band 24 is obtained by impregnating a non-woven tape 32 described later with a resin liquid 38 described later and curing it.

  In this case, the nonwoven fabric tape 32 can be used as an example of a material that can penetrate and permeate the resin liquid 38 described later in the manufacturing process of the coil 10 described later and can be wound around the second unit litz wire 18. It is a thing. If it has such a characteristic, the raw material which comprises the surrounding band 24 may not be limited to the nonwoven fabric tape 32. FIG.

  In the second unit litz wire 18, an insulating cured resin 20 (resin) exists between the plurality of strands 14 or between the plurality of first unit litz wires 16 without any gap. Further, the cured resin 20 is present between the element wire 14 and the lashing band 22 and the surrounding band 24 and between the first unit litz wire 16 and the lashing band 22 and the surrounding band 24 without any gap.

  That is, the second unit litz wire 18 is obtained by curing a plurality of strands 14 or a plurality of first unit litz wires 16 with a resin liquid 38 described later and solidifying them integrally. It is integrated and fixed to.

  Further, in the litz wire 12, the strand 14, the first unit litz wire 16, the second unit litz wire 18, the securing band 22, and the surrounding band 24 are solidified by the cured resin 20 without any gaps. That is, the coil 10 and the litz wire 12 constituting the coil 10 have a configuration in which the space between the strands 14 and the periphery thereof is filled with the cured resin 20 without a gap and molded.

  As the cured resin 20, that is, a resin liquid 38 to be described later, a resin having high thermal conductivity, that is, high heat dissipation may be adopted. As the resin having a high thermal conductivity, for example, an epoxy resin obtained by adding a micro-sized high thermal conductive filler such as alumina or boron nitride as an additive for developing high thermal conductivity is used.

  When a resin having high thermal conductivity is adopted, the coil 10 and the litz wire 12 constituting the coil 10 are arranged between the plurality of strands 14, between the plurality of first unit litz wires 16, and between the strand 14 and the lashing band. 22 and the surrounding band 24, and further, the first unit litz wire 16 and the lashing band 22 and the surrounding band 24 are filled with the cured resin 20 having high thermal conductivity, that is, high heat dissipation without gaps. Yes.

  Therefore, the coil 10 to be formed and the litz wire 12 constituting the coil 10 are filled with the cured resin 20 having a high thermal conductivity, that is, a high heat dissipation property without gaps, and the outer periphery is also filled with the cured resin 20 having a high heat dissipation property. Since it is covered with the hardened encircling band 24, the entire coil 10 has high thermal conductivity, that is, heat dissipation.

  Next, a method for manufacturing the coil 10 will be described. 3 to 9 are views for explaining a method of manufacturing the coil 10, and are diagrams illustrating states in each intermediate process of the manufacturing process. 3A and 3B are views showing a state in the middle of the manufacturing process of the litz wire 12 constituting the coil 10, FIG. 3A is a perspective view, and FIG. 3B is a cross-sectional view.

  4A and 4B are views showing a state in the middle of the manufacturing process of the litz wire 12 constituting the coil 10, wherein FIG. 4A is a perspective view and FIG. 4B is a cross-sectional view. FIG. 5 is a view showing a state in the middle of the manufacturing process of the litz wire 12 constituting the coil 10, FIG. 5 (a) is a perspective view, and FIG. 5 (b) and FIG. 5 (c) are sectional views. .

  First, as shown in FIGS. 3A and 3B, a twisted litz wire 30a (Litz wire) is prepared. The twisted litz wire 30a is formed by twisting the strands 14 to create the first unit litz wire 16, and then twisting the first unit litz wire 16. What twisted the litz wire 30 a with the cured resin 20 corresponds to the second unit litz wire 18.

  Next, as shown in FIGS. 4 (a) and 4 (b), the periphery of the twisted litz wire 30a is secured by being wound by a lashing band 22 to form a secured litz wire 30b (Litz wire). To do. The tying band 22 is wound around the twisted litz wire 30a so as to form a gap, that is, a gap.

  In this state, the twisted litz wire 30a is exposed from the gap between the lashing bands 22 to be wound. Here, since the tying band 22 is, for example, an aramid paper tape, it cannot transmit a resin solution described later.

  Next, as shown in FIGS. 5A and 5B, the bandage litz wire 30 c (Litz wire) is formed by winding the periphery of the secured litz wire 30 b with the nonwoven fabric tape 32. In this case, the nonwoven fabric tape 32 is wound around the secured litz wire 30b so that no gap is generated between the wound nonwoven fabric tapes 32. The nonwoven fabric tape 32 can permeate and permeate a resin liquid 38 described later.

  Here, the nonwoven fabric tape 32 contains a curing accelerator for the resin liquid 38 to be described later. Examples of the curing accelerator include amines, imidazoles, phosphines, DBU (1,8-diazabicyclo (5.4.0) undecene-7) and organic acid salts thereof, ammonium or phosphonium compounds.

  And as shown to Fig.3 (a) and (b), the circumference | surroundings of the twisted litz wire 30a are wound around the nonwoven fabric tape 32 without a gap, and thereby the bandage litz wire 30d (Litz wire) shown in FIG. Line) can be formed. In this case, since the lashing by the lashing band 22 can be omitted, the process can be simplified and the manufacturing cost can be reduced.

  Further, in the coil 10 and the litz wire 12 constituting the coil 10 in this case, the periphery of the second unit litz wire 18 is covered with the encircling band 24, and the second unit litz wire 18 and the encircling band 24 are secured between them. The band 22 does not exist. Other configurations are the same.

  Next, as shown in FIG. 6, the bandage litz wire 30 c is wound around the wound core material 34 to form the bandage litz wire 30 c in a coil shape. The wound core material 34 is made of wood, for example. What is formed in the shape of a coil by winding the bandage litz wire 30c around the winding core material 34 becomes a coil 10b as shown in FIG.

  Next, after the coil 10b is removed from the wound core member 34, it is immersed in a resin container 36 filled with a resin solution 38 as shown in FIG. By placing the resin container 36 in a space having a pressure lower than atmospheric pressure, filling of the resin liquid 38 into the coil 10b is promoted.

  Here, as described above, the nonwoven fabric tape 32 can transmit the resin liquid 38. Further, as shown in FIG. 4, the tying band 22 is wound around a twisted litz wire 30a so that a gap G is formed therebetween.

  Therefore, the resin liquid 38 permeates through the nonwoven fabric tape 32 and enters the bandage litz wire 30c, and further passes through the gap G of the wound lashing band 22 to form the first unit litz wire 16 and the strand 14. Penetration in between. Thereby, between the 1st unit litz wire 16 or the strand 14 inside the 2nd unit litz wire 18, Furthermore, the lashing band 22, the nonwoven fabric tape 32, these strand 14, the 2nd unit litz wire 18, etc. The gap is filled with the resin liquid 38 without any gap.

  Here, as described above, the nonwoven fabric tape 32 contains a curing accelerator for the resin liquid 38. With this curing accelerator, the coil 10b is immersed in the resin liquid 38, and after the resin liquid 38 has sufficiently penetrated into the nonwoven fabric tape 32 and the bandage litz wire 30c, the resin liquid 38 in the nonwoven fabric tape 32 reacts with the curing accelerator. Harden.

  Thereby, as shown in FIG. 8 to be described later, a surrounding band 24 cured by the resin is formed. Here, since the curing accelerator is contained only in the non-woven tape 32, only the resin liquid 38 of the non-woven tape 32 is cured, and the internal resin liquid 38 covered with the non-woven tape 32 remains uncured. Remain in.

  That is, the internal region covered with the nonwoven fabric tape 32 between the first unit litz wire 16, the strand 14, and the lashing band 22 inside the second unit litz wire 18 is a resin liquid before curing. 38 or uncured resin 40. The coil in this state is designated as coil 10d, and the litz wire constituting this is designated as bandage litz wire 30e.

  As shown in FIG. 8, in the bandage litz wire 30e constituting the coil 10d, the uncured resin 40 is filled between the element wires 14 and between the first unit litz wires 16, and the outer periphery is filled with the resin. The nonwoven fabric tape 32 cured by the liquid 38, that is, is covered with the surrounding band 24.

  Next, the coil 10d in this state taken out from the resin container 36 is shown in FIG. The structure of the bandage litz wire 30e constituting the coil 10d is shown in FIG. 8 as described above. FIG. 8 shows a cross-sectional structure of portion B in FIG.

  At this time, the bandage litz wire 30e constituting the coil 10d is covered with the band 24 whose periphery is hardened with the resin liquid 38 as described above. Therefore, even if the coil 10d is taken out from the resin container 36, the resin liquid 38 inside the coil 10d, that is, the uncured resin 40, can be prevented from leaking to the outside, and there is no gap in the interior covered by the enveloping band 24. A held state is secured.

  Next, as shown in FIG. 9, the coil 10 d is put into the thermal drying furnace 42. The entire coil 10d is thermally dried by the heat drying furnace 42, whereby the uncured resin 40 of the coil 10d is cured. At the same time, hardening of the surrounding band 24 is promoted. The coil 10 shown in FIG. 1 can be manufactured through the above steps.

  In the step shown in FIG. 7, only the 32 parts of the non-woven tape is included in the curing accelerator and the resin liquid 38 in only this part is cured for the following reason. Assume that the nonwoven fabric tape 32 portion does not contain the curing accelerator of the resin liquid 38.

  In this case, even if the coil 10b is immersed in the resin liquid 38 in the resin container 36, the resin liquid 38 in the portion of the nonwoven fabric tape 32 is not cured. In this state, when the coil 10 is taken out from the resin container 36, the nonwoven fabric tape 32 allows the resin liquid 38 to pass therethrough, so that the uncured resin 40 in the coil 10 passes through the nonwoven fabric tape 32 and leaks outside.

  Accordingly, in this state, when the resin liquid 38 is cured in the thermal drying furnace 42, the cured resin 20 is lost inside the litz wire 12 constituting the coil 10, and the strand 14, the first unit litz wire 16, the second A gap is formed between the unit litz wire 18, the securing band 22, the surrounding band 24, and the like. If such a gap exists, the insulating property of the coil 10 is lowered.

  On the other hand, in order to cure the resin liquid 38 when the nonwoven fabric tape 32 does not contain a curing accelerator, the resin liquid 38 is cured by a method such as heating with the coil 10 placed in the resin container 36. .

  However, if it does in this way, the resin liquid 38 will harden | cure with the resin container 36 in which the coil 10 was put, and since these are integrated with the resin container 36, the coil 10 cannot be taken out. Further, the cured resin is also filled in the cavity at the center of the coil 10, and the cavity is blocked with the cured resin.

  For the above reason, the resin liquid 38 is cured only in this portion by adding a curing accelerator to the nonwoven fabric tape 32. That is, the nonwoven fabric tape 32 becomes a surrounding band 24 cured by the resin by adding a curing accelerator to the nonwoven fabric tape 32, the coil 10b is immersed in a resin container 36 filled with the resin liquid 38, and the resin liquid 38 is contained therein. When impregnated, the coil 10b has a function of maintaining a state in which the resin liquid 38 is filled without a gap.

  Thereby, there is no gap between the element wire 14, the first unit litz wire 16, the second unit litz wire 18, the lashing band 22 and the surrounding band 24 inside the coil 10, and the coil 10 with improved insulation can be obtained. it can.

According to the coil 10 of the aspect mentioned above, there exist the following effects.
The coil 10 and the litz wire 12 constituting the coil 10 have a configuration in which the space between the strands 14 and the periphery thereof are filled with a cured resin 20 without a gap and molded. Thereby, the insulation of the coil 10 is improved. For example, even when this is used in a high-frequency electric device, excellent insulation is achieved.

  Further, in the coil 10 and the litz wire 12 constituting the coil 10, the strand 14, the first unit litz wire 16, the second unit litz wire 18, the lashing band 22, and the surrounding band 24 are integrated with the cured resin 20 to form a gap. The structure is solidified and fixed in three dimensions. That is, the coil 10 and the litz wire 12 constituting the coil 10 have a configuration in which the space between the wires 14 and the periphery thereof are filled with the cured resin 20 without any gaps, and are solidified and molded. Thereby, in the coil 10, generation | occurrence | production of a clearance gap and a peeling void is suppressed and there exists outstanding insulation.

  The coil 10 and the litz wire 12 constituting the coil 10 are covered with a surrounding band 24 made of a non-woven tape 32 cured with resin. Thereby, the insulation between the litz wires 12 is improved and the mechanical strength of the coil 10 is improved.

  In the coil 10 and the litz wire 12 constituting the coil 10, a resin having a high thermal conductivity, that is, a high heat dissipation property may be employed as the cured resin 20, that is, the resin liquid 38 used for the coil 10. In this case, since the coil 10 has excellent heat dissipation, for example, even when abnormal heat generation occurs in the coil 10, damage to the coil 10 and the like can be suppressed.

  According to the method for manufacturing the coil 10, the nonwoven fabric tape 32 contains the curing accelerator for the resin liquid 38. With this curing accelerator, the coil 10b being manufactured is immersed in the resin liquid 38, and after the resin liquid 38 has sufficiently penetrated into the bandage litz wire 30c, the resin liquid 38 in the nonwoven fabric tape 32 reacts with the curing accelerator and cures. To do.

Thereby, the inner region of the coil 10 is filled with the uncured resin liquid 38, that is, the uncured resin 40, and the outer periphery thereof is covered with the non-woven tape 32 that is cured with the resin liquid 38, that is, the surrounding band 24. Become.
That is, the outer periphery of the uncured resin 40 in the inner region of the coil 10 is covered by the surrounding band 24 solidified by the resin, and a state in which the uncured resin 40 is confined inside can be created.

Thereby, even if it takes out the coil 10 in the middle of manufacture from the resin container 36, it can prevent the unhardened resin 40 of the internal area | region of the coil 10 from leaking out. Thereby, it is possible to obtain the coil 10 having a configuration in which the space between and around the strands 14 and the periphery thereof is filled with the cured resin 20 without a gap and molded, and the litz wire 12 constituting the coil 10.
As described above, for example, even when this is used in a high-frequency electric device, the coil 10 having excellent insulating properties can be manufactured.

The above description includes the following configurations.
The coil is a winding conductor in which conductive thin wires are bundled and molded with a resin, and is composed of a winding conductor in which the resin is filled with no gap between the thin wires.
The periphery of the winding conductor is covered with a non-woven fabric cured by resin.
The circumference of the winding conductor is wound with a tape having a property of not transmitting the resin before being cured.

A resin with high thermal conductivity is used.
Additives that exhibit high thermal conductivity are added to the resin.
Moreover, before the process of winding the circumference | surroundings of the conductor for winding with the nonwoven fabric containing a resin hardening accelerator, the process of winding it providing a space | interval with the tape provided with the property which does not permeate | transmit a liquid resin is provided.
Additives that exhibit high thermal conductivity are added to the resin.

<Coil using a square wire as the conductor>
Hereinafter, a coil using a square wire as a conductor will be described with reference to FIGS. The flow of the manufacturing method is the same as that of the coil using the litz wire described above, and will be described with reference to FIGS.

  FIG. 10 is a cross-sectional view showing the configuration of part A of the coil 110 (see FIG. 1). This portion A is a portion corresponding to the basic unit of the multiconductor wire 12. The coil 110 is composed of a multiconductor wire 12 made of, for example, copper. As shown in FIG. 1, the coil 110 is configured such that, as shown in FIG. 1, the multiconductor wire 12 has a cavity at the center and is concentrically formed, for example, an ellipse, and is wound in close contact with a spiral, and the entire resin wire 12 It is hardened by.

  The multiconductor wire 12 used for the coil 110 is a winding conductor composed of a plurality of, for example, two conductive strands 14 insulated from each other, for example, a plurality of enamel wires provided with an insulating film. The multi-conductor wire 12 is formed by covering the periphery of the plurality of strands 114 with a securing band 22 and a surrounding band 24.

  As the tying band 22, for example, a strong aramid fiber tape is used. The tying band 22 has a paper tape shape, and is used to tie up each strand 114 so as not to be unwound. As shown in FIG. 12A, which will be described later, the tying band 22 is wound around the multi-conductor wire 12 so that a gap G (corresponding to the interval) is formed between the tying bands 22 to be wound. ing.

  The surrounding band 24 winds and covers the periphery of the multiconductor wire 12 secured by the securing band 22. The encircling band 24 is obtained by impregnating a resin liquid 38 into a non-woven tape 32 and curing it. In this case, the nonwoven fabric tape 32 is an example of a material that can penetrate and permeate the resin liquid 38 in the manufacturing process of the coil 110 and can be wound around the multiconductor wire 12. If it has such a characteristic, the raw material which comprises the surrounding band 24 may not be limited to the nonwoven fabric tape 32. FIG.

  Insulating cured resin 20 is present between the plurality of strands 114 without any gaps. In addition, the cured resin 20 exists between the strand 114 and the lashing band 22 and the surrounding band 24 without a gap. That is, the entire coil 110 is three-dimensionally integrated and fixed by the curing resin 20 from the inside to the outside. Further, the securing band 22 and the surrounding band 24 are also solidified by the cured resin 20 without a gap. That is, the coil 110 and the multiconductor wire 12 constituting the coil 110 have a configuration in which the space between the wires 114 and the periphery thereof are filled with the cured resin 20 without a gap and molded.

  As the cured resin 20, that is, the resin liquid 38, a resin having high thermal conductivity, that is, high heat dissipation may be employed. As the resin having a high thermal conductivity, for example, an epoxy resin provided with a step of adding an additive that exhibits high thermal conductivity, and added with a micro-sized high thermal conductive filler such as alumina or boron nitride is used.

  When a resin having high thermal conductivity is adopted, the coil 110 and the multiconductor wire 12 constituting the coil 110 are arranged between the plurality of wires 114, between the wires 114 and the securing band 22 and the surrounding band 24, and The configuration is such that the outer peripheral surface of the coil 110 is filled with the cured resin 20 having high thermal conductivity, that is, heat dissipation.

  Therefore, since the coil 110 and the multiconductor wire 12 constituting the coil 110 are covered with the cured resin 20 on the inner side and the outer peripheral side, the coil 110 and the multiconductor wire 12 as a whole exhibit high thermal conductivity, that is, heat dissipation. Further, since the residual voids that are likely to become defects during insulation are minimal and the adhesion between the conductor portion and the resin is good, the insulation performance is high.

  The coil 110 is secured by winding a plurality of, for example, two strands 114 and winding the periphery of the strand 114 with a tie strap 22 as shown in FIGS. 12 (a) and 12 (b). The multiconductor wire 12 is formed. The securing band 22 is wound so as to form a gap, that is, a gap (G).

  In this state, the strand 114 is exposed from the gap between the lashing bands 22 to be wound. Here, since the tying band 22 is, for example, an aramid paper tape, it cannot transmit a resin solution described later. That is, the tying band 22 has a property of not allowing the resin liquid before being cured to pass therethrough.

  Next, as shown in FIGS. 13A and 13B, the periphery of the securing wire 30 b is wound with a nonwoven fabric tape 32. In this case, the nonwoven fabric tape 32 is wound around the securing wire 30b so that no gap is generated between the wound nonwoven fabric tapes 32. The nonwoven fabric tape 32 can permeate and permeate a resin liquid 38 described later. Here, the nonwoven fabric tape 32 contains a curing accelerator for the resin liquid 38. Thereby, the multiconductor wire 12 shown in FIG.13 (c) is formed.

  Next, as shown in FIG. 6 described above, the multiconductor wire 12 is spirally wound around the winding core material 34 to form the multiconductor wire 12 in a coil shape. The wound core material 34 is made of wood, for example. And after extracting the coil 110b from the winding core material 34, as shown in above-mentioned FIG. 7, it is immersed in the resin container 36 with which the resin liquid 38 was filled. At this time, by placing the resin container 36 in a space having a pressure lower than the atmospheric pressure, filling of the resin liquid 38 into the coil 110b is promoted.

  Here, as described above, the nonwoven fabric tape 32 can transmit the resin liquid 38. Further, as shown in FIG. 12, the tying band 22 is wound around the strand 114 so that a gap G is formed therebetween. Therefore, the resin liquid 38 permeates through the nonwoven fabric tape 32 and penetrates to the outer peripheral surface (surface) of the strand 114, and further penetrates between the strands 114 through the gap G of the wound securing band 22. To do. Thereby, between the strands 114, and also between the lashing band 22, the nonwoven fabric tape 32, and these strands 114 is filled with the resin liquid 38 without a gap.

  As described above, the nonwoven fabric tape 32 is impregnated with the curing accelerator of the resin liquid 38. Therefore, after the resin liquid 38 is immersed in the resin liquid 38 and sufficiently penetrates into the nonwoven fabric tape 32 and the multiconductor wire 12, the resin liquid 38 that has penetrated the nonwoven fabric tape 32 reacts with the curing accelerator and is cured.

  Thereby, the surrounding band 24 hardened | cured with resin is formed. Here, since the curing accelerator is contained only in the non-woven tape 32, only the resin liquid 38 of the non-woven tape 32 is cured, and the internal resin liquid 38 covered with the non-woven tape 32 remains uncured. Remain in.

  That is, as shown in FIG. 14, the interior region between the wire 114 and the lashing band 22 and covered with the nonwoven fabric tape 32 is filled with the resin liquid 38 before curing, that is, the uncured resin 40. On the other hand, the outer peripheral side is covered with the non-woven tape 32 cured by the resin liquid 38, that is, the surrounding band 24.

  For this reason, when taking out from the resin container 36, the internal uncured resin 40 can be prevented from leaking to the outside, and a state in which the inside is covered without any gaps can be ensured. .

  Next, as shown in FIG. 9 described above, the whole is put into a thermal drying furnace 42 and thermally dried, and the uncured resin 40 inside is also cured. At the same time, hardening of the surrounding band 24 is promoted. The coil 110 is manufactured through the above steps. It should be noted that only the 32 parts of the nonwoven fabric tape contains a curing accelerator, and the resin liquid 38 is cured only in this part, as described above, between the wire 114, the lashing band 22 and the surrounding band 24 inside the coil 110. This is to obtain the coil 110 having no gap and improved insulation.

According to the coil 110 of the aspect mentioned above, there exist the following effects.
The coil 110 and the multiconductor wire 12 constituting the coil 110 have a configuration in which the space between the strands 114 and the periphery thereof are filled with the cured resin 20 without a gap and molded. Thereby, the insulation of the coil 110 is improved. For example, even when the coil 110 is used in a high-frequency electric device, excellent insulation is achieved.

  Further, the coil 110 and the multi-conductor wire 12 constituting the coil 110 have a configuration in which the wire 114, the securing band 22, and the surrounding band 24 are solidified by the cured resin 20 without any gap and fixed in a three-dimensional manner. . That is, the coil 110 and the multiconductor wire 12 constituting the coil 110 have a configuration in which the space between the wires 114 and the periphery thereof are filled with the cured resin 20 without gaps, and are solidified and molded. Thereby, in the coil 110, generation | occurrence | production of a clearance gap and a peeling void is suppressed and there exists outstanding insulation.

  The coil 110 and the multi-conductor wire 12 constituting the coil 110 are covered with a surrounding band 24 made of a non-woven tape 32 whose periphery is cured with a resin. Thereby, the insulation between the multiconductor wires 12 is improved, and the mechanical strength of the coil 110 is improved.

  In the coil 110 and the multiconductor wire 12 constituting the coil 110, a resin having a high thermal conductivity, that is, a heat dissipation property may be adopted as the cured resin 20 used for the coil 110, that is, the resin liquid 38. In this case, since the coil 110 has an excellent heat dissipation property, for example, even when abnormal heat generation occurs in the coil 110, damage to the coil 110 and the like can be suppressed.

  According to the method for manufacturing the coil 110, the nonwoven fabric tape 32 contains the curing accelerator for the resin liquid 38. With this curing accelerator, the coil 110b being manufactured is immersed in the resin liquid 38, and after the resin liquid 38 has sufficiently penetrated into the multiconductor wire 12, the resin liquid 38 in the nonwoven fabric tape 32 reacts with the curing accelerator and cures. To do.

  That is, the inner region of the coil 110 is filled with the uncured resin liquid 38, that is, the uncured resin 40, and the outer periphery thereof is covered with the nonwoven fabric tape 32 that is cured with the resin liquid 38, that is, the surrounding band 24. . Thereby, even if it takes out the coil 110 from the resin container 36 in a manufacturing process, it can prevent the unhardened resin 40 of the internal area | region of the coil 110 from leaking out.

  Therefore, it is possible to obtain the coil 110 having a configuration in which the space between and around the strands 114 is filled with the cured resin 20 without gaps and molded, and the multiconductor wire 12 constituting the coil 110, and the coil having excellent insulation. 110 can be manufactured.

  By the way, although the example which uses the flat wire from which cross-sectional view becomes substantially rectangular by bundling a plurality of, for example, two strands 114a and 14b has been shown so far, as shown in FIG. One strand 214 that is rectangular may be used. Even in the case of such a wire 214, the nonwoven fabric tape 32 is wound and immersed in the resin container 36 in the same manner as in the embodiment, so that the resin liquid 38 becomes the wire 114 as shown in FIG. It penetrates to the surface. In this case, lashing by the lashing band 22 may be omitted.

  And it can be set as the multiple conductor wire 12 provided with the outstanding insulation as shown in FIG.15 (c) by heat-processing. Therefore, the coil 110 having excellent insulating properties can be manufactured.

  In the above description, in the embodiment, an example in which a rectangular wire having a rectangular cross section is used as the multiconductor wire 12 has been described. However, the present invention is not limited to this. For example, a round wire having a circular cross section may be used.

<Mode in which conductor is directly covered with non-woven fabric>
Hereinafter, the aspect which directly covers a conductor with a nonwoven fabric is demonstrated, referring FIG. 16 and FIG. The main flow of the manufacturing method is common to the coil using a litz wire as a conductor.

  When a litz wire is used as the above-described conductor or when a plurality of strands 114a and 14b are used, lashing is performed by the tie strap 22 so that each conductor cannot be unwound, but a single strand 214 is used. Therefore, it is considered that it is not always necessary to perform lashing with the lashing band 22.

  Even in other cases, a situation in which lashing by the lashing band 22 is not necessary is conceivable. Specifically, for example, when a non-woven fabric such as the non-woven fabric tape 32 has sufficient strength to tie the conductor, the conductor can be lashed by the non-woven fabric itself. 22 is not considered necessary.

  Therefore, when the nonwoven fabric has sufficient strength, it extends in the full length direction of the strand 314 as shown in FIG. 16A, and covers the strand 314 at a certain length in the full length direction at a time. In addition, as shown in FIG. 16B, the surface of the strand 314 can be covered with a non-woven fabric having a width that allows both ends to overlap in a state where the surface of the strand 314 is covered.

  That is, the surface of the wire 314 can be wrapped with a nonwoven fabric. In this case, a nonwoven fabric that can permeate and permeate the resin liquid 38 like the nonwoven fabric tape 32 can be adopted as the nonwoven fabric.

  Even when such a nonwoven fabric is used, a winding conductor composed of the strand 314 is prepared and the surface of the strand 314 is wrapped with the nonwoven fabric tape 32 as in the case where a litz wire is used as the conductor described above. The wire 314 is directly covered with a non-woven fabric, the winding conductor wrapped in the non-woven fabric is spirally wound to form a coil, and the coiled winding conductor is immersed in the liquid resin to obtain the liquid resin. The coil can be manufactured by a manufacturing method in which the winding conductor impregnated with the liquid resin is treated in a heat drying furnace to cure the resin.

  Since the entire surface of the wire 314 excluding the end face is in direct contact with the nonwoven fabric such as the nonwoven fabric tape 32, the coil manufactured by such a manufacturing method can be obtained by impregnating the resin with the nonwoven fabric. The surface of the line 314 can be filled with resin. Therefore, good insulation can be obtained.

  Further, by using the cloth-like nonwoven tape 32 that can wrap the strand 314 as it is, the nonwoven fabric can be formed on the surface of the strand 314 without any gaps compared with the case where the ribbon-like nonwoven tape 32 is wound. Can be provided. Therefore, workability can be greatly improved.

  Moreover, it can also be set as the structure which covers the strand 314 with a some nonwoven fabric. That is, the strand 314 often has a relatively long overall length, and in that case, there is a possibility that the workability may be lowered if it is attempted to wrap the entire length of the strand 314 at one time with a single nonwoven fabric. Therefore, a plurality of non-woven fabrics are prepared with respect to the full length direction of the strand 314, arranged so that the non-woven fabrics adjacent in the full length direction are in close contact with each other, or the adjacent non-woven fabrics partially overlap each other, By setting the wire 314 to be wrapped with the nonwoven fabric, the entire surface of the wire 314 can be easily covered, and workability can be improved.

In this case, as the element wire 314, the above-described litz wire conductor 14, a plurality of square wire conductors 114, a flat rectangular conductor 214, and a round wire can be used. If the strength of the nonwoven fabric is sufficient, this is a litz wire or a plurality of strands 114.
Moreover, after covering with a nonwoven fabric, as shown in FIG. 17, it can suppress that a nonwoven fabric spreads by winding a fastening member like the tying band 22, for example, and workability | operativity after covering with a nonwoven fabric Can be improved. In this case, the fastening member does not necessarily have to be strong like the tying member 22.

(Other embodiments)
Although several embodiments of the present invention have been described, these embodiments are presented by way of example and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the scope of the invention. These embodiments and modifications thereof are included in the scope and gist of the invention, and are included in the invention described in the claims and the equivalents thereof.

  In the drawings, 10, 10 b, 10 c, 10 d, 110 are coils, 12 is a litz wire (conductor, multi-conductor wire, conductor for winding), 14, 114, 214, 314 is a strand (conductor, conductor for winding) , 20 is a cured resin (resin), 22 is a lashing band, 24 is an encircling band, 32 is a non-woven tape, 36 is a resin container, 38 is a resin liquid (resin, liquid resin), 40 is an uncured resin (resin), Reference numeral 42 denotes a heat drying furnace.

Claims (3)

A coil formed by winding a winding conductor obtained by molding a conductive conductor with a resin,
The winding conductor is a coil in which the conductor is directly covered with a nonwoven fabric.   The coil according to claim 1, wherein the conductor covered with the nonwoven fabric is wound with a tape that does not transmit a liquid resin. Preparing a winding conductor composed of a conductive conductor;
Directly covering the conductor of the winding conductor with a nonwoven fabric;
A step of spirally winding the winding conductor wrapped in the nonwoven fabric into a coil;
Immersing the coiled winding conductor in a liquid resin and impregnating the liquid resin;
Curing the resin by treating the winding conductor impregnated with the liquid resin in a heat drying furnace;
The manufacturing method of the coil containing this.

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