JP2544622Y2 - Mold coil - Google Patents

Description

[Detailed description of the invention]

[0001]

BACKGROUND OF THE INVENTION This invention relates to a molded coil.

[0002]

2. Description of the Related Art In general, a molded coil has a structure in which the periphery of a winding is molded with a synthetic resin or a fiber-reinforced synthetic resin. Winding is insulated wire
Although formed have wound, when the winding-out the number of times that many necessary, be put-out around the multilayer. The layers of wire having a reduced small to potential gradient winding-out number per layer if the potential gradient between the layers is higher than a certain set value to a desired value in such a multi-layer winding formed in multiple stages, A so-called multi-stage winding is employed. Thus the inner and outer peripheral surfaces and layers of such windings, fibers for reinforcing molding resin layer are attached come up. A glass fiber chop strand mat is generally used as the reinforcing fiber, and a thermosetting resin such as an epoxy resin is generally used as the mold resin. Glass fiber has high elasticity and good adhesiveness with epoxy resin, so that the mold resin layer can be greatly reinforced. But the volume
When the abnormal large current flows through the line, a mold resin layer reinforced with glass fibers occurs even cracks subjected to thermal shock due to the large Joule heat, referred to it often occurs that become unplayable There is a problem. The inventor has conducted various studies for the purpose of obtaining a molded coil with less occurrence of such cracks, and completed the present invention.

[0003]

Means for Solving the Problems In order to solve the above problems, a first aspect of the present invention is to provide a molded coil having a mold layer formed around a winding, wherein the winding is formed as a multilayer winding. Glass fiber around the winding layer inside this multilayer winding
The polyester fiber nonwoven fabric around the outermost winding layer wound
The coil was wound to form a mold layer of a thermosetting resin reinforced in two stages, thereby forming a molded coil. The second invention is, in order to solve the above problems, in the molding coils mold layer is formed around the winding, the winding is formed in multiple stages windings, each stage of the multi-stage winding Winding glass fiber around the winding layer <br/> Wound polyester fiber non-woven fabric between steps
The molded coil was characterized by forming a fiber- reinforced thermosetting resin mold layer.

[0004]

[Function] When a large abnormal current flows through the winding, a large Joule heat is generated and thermal expansion occurs, causing stress distortion inside . Around the outermost winding layer of the multilayer winding where the stress distortion is maximized. Since the polyester fiber non-woven fabric having an elongation rate greater than the elongation rate of the glass fiber is wound and molded with a thermosetting resin, a large amount of stress distortion can be absorbed and cracks can be prevented. Further, in the multi-stage winding, stress distortion caused by thermal expansion can be absorbed since a polyester fiber nonwoven fabric having a larger elongation rate of glass fiber is wound between the stages and molded with a thermosetting resin, so that cracks can be prevented. .

[0005]

EXAMPLE 1 The invention of claim 1, the submission drawings 1
With reference to FIG, number of layers of windings will be described with reference to the embodiment of the molded coil in the case of four layers. First, a four-layer winding is manufactured. To produce a four-layer winding , the mandrel must have an areal density of 4
Thickness in 00~500g / ^{m 2} is a chopped strand mat _{2 1} by the glass fibers of about 0.7~0.8mm
Wound can, to form a first flat winding-out line layer 5 ₁ winding-out <br/> attached to come flat winding insulation covered rectangular conductor wire 4 thereon. The attaching can wind the chop Dos land mat 2 ₂ glass fibers first spur on the winding <br/> feeder layer 5 _1, insulating folded back from the end-out first spur winding-out line layer 5 _first winding thereon the covered rectangular conductor wire 4 wound <br/> came to come flat wound to form a second flat winding-out line layer 5 _2. This second flat
Winding-out with can wind the chopped strand mat 2 ₃ glass fibers on the wire layer 5 _2, on the second flat winding-out line layer 5 Part ₂
Put can wind the insulating covered rectangular conductor wire 4 folded back from the end-out around the can flat wound to form a third planar winding-out line layer _3. The first Mihira winding-out line layer ₅ with a surface density over ₃ and a thickness 450 g / ^{m 2} can wind the polyester fiber nonwoven fabric _{3 1} of 0.8 mm <br/> only,-out first Mihira winding thereon the insulation covered rectangular conductor wire 4 folded back from the end-out winding of the wire layer ₃ put come around the can flat winding Saisototaira
Forming a winding layer _{5 4.} After surface density over the top Hokahira winding-out line layer ₄ is fixed with can wind the polyester fiber nonwoven fabric _{3 2} 0.8mm and a thickness 450 g / ^{m 2,} to obtain a four-layer windings removed from the mandrel be able to. Next, a mold layer is formed around the four-layer winding. This mold layer can be formed by setting a four-layer winding in a mold, injecting an epoxy resin liquid into the mold, and heating and curing the liquid. After the mold layer of the epoxy resin is formed in this manner, the mold coil 1 is removed from the mold and subjected to post-processing if necessary, thereby obtaining the molded coil 1 having a four-layer winding. The molded coil 1, a polyester fiber nonwoven fabric 3 _1, 3 ₂ curing epoxy resin 6 ₂ reinforced with is formed around the outermost fourth flat winding-out line layer _4, the first winding layer-third volume become those cured epoxy resin ₆₁ reinforced with glass fibers around the line layer is formed.

[0006]

EXAMPLE 2 The invention of claim 2, the submission drawings 2
With reference to FIG., The number of stages of the winding will be described with reference to examples of molded coil in the case of three stages. First, a three-stage winding is manufactured. To produce a three-stage winding , the mandrel must have an areal density of 4
00～500G / chopped thickness by the glass fibers of about 0.7~0.8mm in ^{m 2} strand mat 12 ₁
The Paste can wound, it can flat winding insulation covered rectangular conductor wire 14 thereon
Wound to form a first spur winding-out line layer 15 ₁ of the first-stage. With can wind the chopped strand mat 12 ₂ glass fibers on the first stage of the first spur winding-out line layer 15 _1,
With wound care flat winding insulation covered rectangular conductor wire 14 folded back from the end-out first spur winding-out line layer 15 ₁ of the winding of the first stage on the
Only to form the first stage of the second flat winding-out line layer 15 _2. The attaching can wind the chopped strand mat 12 ₃ of the glass fiber on the second flat winding-out line layer 15 _2, folded back from the end-out first-stage second flat winding-out winding of the line layer 15 ₂ on its insulation covered rectangular conductor wire 14 flat winding can first Mihira the first stage with come up on
The winding-out line layer 15 ₃ is formed, a chopped strand mat 12 ₄ of glass fiber was fixed with can wound thereon, a first
The stage winding part 16 is formed. It provided the predetermined interval and the first Danmaki line unit 16, in the same manner as the first Danmaki line section 16 to form a second stage of the winding portion 26. At that time, the second
Th stage of the first layer flat winding-out line 25 ₁ is used pull from end-out third layer flat winding-out line 15 _third winding of the first stage. With a predetermined interval following the second Danmaki line unit 26, in the same manner as the second Danmaki line section 26 to form a third stage of the winding portion 36.
After that , between the first-stage winding portion 16 and the second-stage winding portion 26 and between the second-stage winding portion 26 and the third-stage winding portion 36 ,
Areal density with come winding polyester fiber nonwoven fabric ₁₃ 1 of 0.8 mm, 13 ₂ thickness at 450 g / ^{m 2,} until its height becomes substantially the same as the height of the winding portions 16, 26, 36 of each stage after fixing put come winding, it is possible to obtain a 3-stage winding remove from the mandrel. Next, a mold layer is formed around the three-stage winding. The mold layer sets a three-stage winding mold, injecting the epoxy resin solution in the mold can be formed by heat curing the
I can . In this way, a mold layer of epoxy resin is formed
After that, the molded coil 11 is removed from the mold and subjected to post-processing if necessary, thereby obtaining a three-stage wound molded coil 11. The molded coil 11 is provided between the first winding section 16 and the second winding section 26 and between the second winding section 26 and the third winding section 36. polyester fiber nonwoven fabric ₁₂ 1, 12 ₂ cured epoxy resin 16 ₂ reinforced with is formed between, the first stage winding section 16 second stage winding
The wire portion 26 and the third-stage winding portion 36 are arranged around the winding layer.
Become those cured epoxy resin 16 ₁ reinforced with glass fibers is formed.

[0007]

Comparative Example 1 The polyester fiber nonwoven fabric 3 _{1 of} Example 1
3 ₂ instead of glass fiber chopped strand mat 2 _4, 2 ₅ outside using the same conditions as example 1, a molded coil of Comparative Example 1.

[0008]

Comparative Example 2 Non-woven fabric of polyester fiber 1 of Example 2
3 _1, 13 ₂ of the glass fiber chopped strand mat ₁₂ 5 instead, 12 outside using ₆ under the same conditions as in Example 2 was fabricated mold coil of Comparative Example 2.

[0009] molded coil of Example 1 and Comparative Example 1,
An acceleration test was performed by passing a current abnormally larger than the rated current of the molded coil of Example 1 to compare the occurrence of cracks in the molded resin layer. Mold coil of Example 1
Has been found to withstand large currents.

[0010] molded coil of Example 2 and Comparative Example 2,
An acceleration test was performed by passing a current abnormally larger than the rated current of the molded coil of Example 2 to compare the occurrence of cracks in the molded resin layer. Example 2 mold carp
Has been found to withstand large currents.

[0011]

As described above, the molded coil of the present invention absorbs internal stress distortion due to thermal expansion and contraction during operation with the thermosetting resin reinforced with the polyester fiber nonwoven fabric, so that cracks are reduced. In addition , polyester fiber
Since the thermosetting resin shrinks due to heating during heat curing , there is also an effect that air voids staying inside the mold layer reinforced with the polyester fiber nonwoven fabric can be reduced.

[Brief description of the drawings]

FIG. 1 is a three-dimensional sectional view illustrating an embodiment of the first invention.

FIG. 2 is a three-dimensional sectional view illustrating an embodiment of the second invention.

[Explanation of symbols]

1,11 ...... molded coil 2 _{1, 2} 2, _{2 3} ...... chopped strand mat 12 ₁ by glass fibers, _{12 2,} 12 3, 12 ₄ ...... chopped strand mat 3 ₁ by glass fibers, ₃ 2, _{3 3} , _{3 4} ...... polyester fiber nonwoven 4,14 ...... insulating covered rectangular conductor wire 5 _{1, 5 2,} 5 3, _{5 4} ...... flat winding layer 15 _{1, 15} 2, 15 ₃ ...... flat winding layer

Claims (2)

(57) [Scope of request for utility model registration] In a molded coil in which a mold layer is formed around a winding, a winding is formed into a multilayer winding, and glass fibers are wound around an inner winding layer of the multilayer winding.
Wrap a polyester fiber nonwoven around the winding layer ,
A molded coil comprising a thermosetting resin mold layer reinforced with fibers in two stages . 2. A molded coil having a mold layer formed around a winding, wherein the winding is formed into a multi-stage winding, and glass fibers are wound around each winding layer of the multi-stage winding. by winding a polyester fiber non-woven fabric, the fiber in two stages
Molded coil, characterized in that the formation of the Wei reinforced molded layer.