JP2604473B2 - Manufacturing method of resin mold coil - Google Patents

Description

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a resin molded coil of a molded transformer.

2. Description of the Related Art A conventional method of manufacturing a resin-molded coil includes disposing an insulating material on an inner peripheral surface and an outer peripheral surface of a coil body made of an interlayer insulating material and a conductor, and then storing the insulating material in a mold and injecting a molding resin. The system has been adopted.

FIG. 4 shows a partial schematic cross-sectional view of the conventional resin molded coil obtained in this manner, and a method of manufacturing the conventional resin molded coil will be described with reference to FIG. In FIG. 4, a winding core (not shown) is wound with a semi-cured insulating material or an inner circumferential insulating material 11 formed by laminating the semi-cured insulating material with a plastic film such as polyester. A coil body 12 is formed by winding an interlayer insulating material made of a plastic film or a porous fiber material and a conductor such as an aluminum foil or a copper foil. Next, an outer peripheral insulating material 13 such as a glass cloth or a polyester nonwoven fabric is wound around the outer periphery of the coil body 12, stored in a mold 15, resin-molded, and heat-cured to mold resin layer 14.
To form

Problems to be Solved by the Invention However, in the above-mentioned conventional method for manufacturing a resin-molded coil, a resin-casting mold is required, and depressurization casting is required to form a uniform mold resin layer. . Furthermore, when a conductor requiring high tension, such as an aluminum-based or copper-based conductor, is used as the conductor of the coil body 12, there is a problem that the inner circumferential insulating material slips during the winding operation, and the winding operation is difficult.

An object of the present invention is to solve the above-mentioned conventional problems, and an object of the present invention is to provide a method for manufacturing a resin mold coil that does not require slippage and does not require casting.

Means for Solving the Problems In order to solve the above problems, a method of manufacturing a resin molded coil according to the present invention is directed to a method of manufacturing a resin-molded coil, comprising the steps of: Insert the protruding plastic film part at the tip of the first insulating layer, which is attached to the film with its position shifted, wind it one or more times, and heat the semi-cured insulating material at the end of winding to overlap. A first step of heat-sealing a portion of the semi-cured insulating material, a second step of winding a layered insulating material and a conductor around the outer periphery of the first insulating layer to form a coil body,
A third step of winding and forming a second insulating layer containing a semi-cured insulating material on the outer periphery of the coil body; and forming a groove formed by the end face of the coil body and the first and second insulating layers. And a fourth step of filling and curing the mold resin.

According to the above configuration, first, the plastic film portion at the tip of the first insulating layer is inserted into a slit provided in the core, and then the first insulating layer is wound around the outer periphery of the core, and the interlayer is further formed on the outer periphery. Since the coil body is formed by winding the insulating material and the conductor, the first insulating layer hardly slips due to the tension of the conductor. In addition, since the first insulating layer and the second insulating layer have a function as a mold and are filled with a mold resin from a coil end surface and a groove formed by the two insulating layers, a resin mold that does not require a mold is used. Becomes possible.

Embodiment Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

FIG. 1 is a perspective view of a core used in the method of manufacturing a resin molded coil of the present invention, FIG. 2 is a front view for explaining a method of manufacturing a resin molded coil of one embodiment of the present invention, and FIG. FIG. 3 is a partially omitted perspective view for explaining resin molding.

In FIG. 1, a core 1 includes an upper core 1a and a lower core 1a.
1b, and the dividing line 1c is formed obliquely so that it can be easily removed after molding. On one side, for example, the upper winding core 1a has a slit portion in a direction orthogonal to the winding direction of the coil conductor. 2 are provided.

In FIG. 2, an inner peripheral insulating material 3 to be a first insulating layer
Is formed by laminating a plastic film 4 and a semi-cured insulating material 5 at different positions. The plastic film 4a protruding from the winding start end of the inner peripheral insulating material 3 is inserted into the slit 2 of the winding core 1. The semi-cured insulating material 5a at the end of the winding is heated and fixed to the semi-cured insulating material 5 at the overlapping portion by heat fusion. The plastic film 4 used here is, for example, polyethylene terephthalate having a thickness of 250 microns, and the semi-cured insulating material 5 is, for example, a glass cloth impregnated with a semi-cured epoxy resin.

Next, the conductor and the interlayer insulating material to which the rising plate 6 is fixed in advance are fixed to the inner peripheral insulating material 3, and the coil is wound by a specified number of times to form the coil body 7. After the rising plate 6 is fixed to the winding end portion in the same manner as the winding start portion, the outer peripheral insulating material 8 serving as the second insulating layer is wound and mounted. When a material obtained by laminating a semi-cured insulating material and a plastic film as the outer peripheral insulating material 8 is used, the semi-cured insulating material is placed inside so as to have good adhesion at the time of resin molding. Next, a mold resin 9 is filled into the groove formed by the end face of the coil body 7 and the inner peripheral insulating material 3 and the outer peripheral insulating material 8 and cured. When an epoxy resin is used as the mold resin 9, as a semi-cured insulating material of the inner peripheral insulating material 3 and the outer peripheral insulating material 8, it is better to use an epoxy resin impregnated porous material, for example, a glass cloth or the like. Adhesion is obtained. Finally, the core 1 is disassembled and removed.

Effect of the Invention As described above, according to the method of manufacturing a resin-molded coil of the present invention, first, a part of the first insulating layer is inserted into the slit portion of the core to prevent slippage, and then wound one or more turns and fixed. Therefore, even when a coil body is manufactured by winding a conductor having a large thickness, there is no difficulty in winding work due to sliding of the first insulating layer. Further, since the molding resin is injected into the groove formed by the first and second insulating layers and the coil end face, a molding die is not required, the number of working steps is reduced, and the direct material cost is reduced. It is effective in reducing the amount of water, and the effect is great.

[Brief description of the drawings]

FIG. 1 is a perspective view of a winding core used in the present invention, FIG. 2 is a front view for explaining an arrangement of an inner peripheral insulating material in a method of manufacturing a resin molded coil according to one embodiment of the present invention, and FIG. FIG. 4 is a partially omitted perspective view for explaining resin molding in the method for manufacturing the resin molded coil, and FIG. 4 is a schematic sectional view for explaining a method for manufacturing a conventional resin molded coil. 1 ... core, 2 ... slit part, 3 ... inner circumference insulating material,
4 ... Plastic film, 5 ... Semi-cured insulating material, 6 ... Rising plate, 7 ... Coil body, 8 ... Outer peripheral insulating material, 9 ... Mold resin.

 ──────────────────────────────────────────────────の Continued on the front page (72) Inventor Shigeru Hirano 1006 Kazuma Kadoma, Osaka Prefecture Matsushita Electric Industrial Co., Ltd. In-house (56) References JP-A-58-39008 (JP, A)

Claims (1)

(57) [Claims] A semi-cured insulating material and a plastic film are attached to a slit provided in a winding core in a direction orthogonal to a winding direction of a coil conductor at a position shifted from a leading end of a first insulating layer. Insert the plastic film and insert 1
A first step of heating the semi-cured insulating material at the end of the winding and thermally fusing the semi-cured insulating material to the semi-cured insulating material at the overlapping portion, and an interlayer insulating material on the outer periphery of the first insulating layer A second step of winding a coil and a conductor to form a coil body; a third step of winding and forming a second insulating layer containing a semi-cured insulating material on the outer periphery of the coil body; And a fourth step of filling and curing a mold resin in a groove formed by the end face and the first and second insulating layers and curing the resin.