JP2854780B2 - Mold coil - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molded coil in which a conductor coil such as a ground coil for a magnetic levitation railway is embedded in a molding resin such as FRP.

[0002]

2. Description of the Related Art Conventionally, among terrestrial coils for a magnetic levitation type railway, a coil used as a levitation coil has a plurality of conductor coils arranged and connected on the same plane, and embedded in a mold resin. To form a molded coil.

[0003] Such a molded coil is disclosed in, for example, Japanese Patent Application Laid-Open No. 4-168704. FIGS. 4A and 4B are views showing the shape of such a conventional levitation coil for a magnetically levitated railway, in which FIG. 4A is a front view showing a tentatively formed state before molding, FIG. 4B is a side view thereof, and FIG. A front view showing a state after molding, and (d) is a side view thereof.

The internal insert coil is manufactured by the following procedure. Unit coils 1a, 1b, 2a, and 2b are formed by superposing and serially connecting basic coils obtained by winding an insulated conductor (element wire) a plurality of times into a predetermined shape, and two unit coils for each set. 1a, 1b and 2a, 2b are connected in a figure-eight arrangement so that the winding directions are opposite to each other to form two sets of levitation coils 1, 2,
2 is an internal insert coil.

The two sets of floating coils 1 and 2 are arranged so as to be closely arranged on the same plane, and are integrally molded with a molding resin 12 such as FRP. 3
Are guide terminals for the floating coils 1 and 2 of each set.

The internal insert coils 1 and 2 are apt to be displaced when the molding resin 12 is molded by SMC (sheet molding compound) or the like. a)
As shown in the figure, between the unit coils 1a and 1b, between 2a and 2b,
The inner insert coils 1 and 2 are tentatively formed by sintering by bundling and heat-treating between 1a and 2a and between 1b and 2b with an insulating tape such as a prepreg tape 4.

In the SMC molding, after setting the floating coils 1 and 2 together with an SMC material (mold resin material) in a molding die (lower die), the upper die is sealed and heated and pressed. A molded coil as shown in FIG. 4 (c) is obtained.

[0008] As other conventional examples, for example,
As disclosed in Japanese Patent Application Laid-Open No. 2-135712, when a cast coil is formed by arranging conductors in a plurality of layers and a plurality of stages, an insulating spacer is interposed between conductors and between a conductor and a mold to form a resin. Is cast into a mold to form a casting coil. In this case, the insulating spacer is bonded to the conductor via an adhesive or is fitted to the conductor by fitting.

[0009]

SUMMARY OF THE INVENTION Among the above prior arts,
When the conductor coils (internal insert coils) are baked together with only the prepreg tape when forming the molded coil, the binding force is weak, and the inside of the mold resin is reduced due to the pressure during molding. It has not been possible to sufficiently cope with the problem of relative displacement of the insert coil. This displacement of the coil causes uneven thickness of the mold material and causes insulation deterioration, and furthermore, in the case of a magnetic levitation type ground coil for a railway, causes a loss of uniformity of magnetic levitation force applied to the train. .

The casting coil disclosed in Japanese Patent Application Laid-Open No. 2-135712 is a technique in which the space between the conductors (element wires) of the casting coil is insulated by spacers. Can be attached to the conductor with an adhesive or a fitting method. However, heavy internal insert coils such as the above-mentioned magnetic levitation type ground coil for railways can be attached by such a simple adhesive or a fitting method. It is impossible to combine the coils, and again, it cannot withstand the pressing force at the time of molding, and a relative displacement occurs between the coils, which is inappropriate.

SUMMARY OF THE INVENTION The present invention has been made in view of the above points, and an object of the present invention is to reduce the displacement of the relative position of an internal insert coil and the accompanying uneven thickness of a molding material, thereby preventing problems such as insulation deterioration. It is to provide a high quality molded coil.

[0012]

Means for Solving the Problems To achieve the above object, the present invention basically provides a molded coil in which a plurality of conductor coils wound a plurality of times are embedded in a mold resin in a predetermined arrangement. A spacer is loaded between the conductive coils, and the spacer and the plurality of conductive coils are molded in a state in which the spacer and the plurality of conductive coils have been integrated by baking using a thermosetting resin in advance. Suggest.

[0013]

According to the above construction, a plurality of conductor coils (inner insert coils) and spacers can be firmly integrated in a preliminary molding process by baking using a thermosetting resin in advance. By filling the empty space between the conductor coils with the coil integrated spacer, it is possible to promote the suppression of the displacement of the conductor coils (for example, even if the corners of the conductor coils are rounded as shown in FIG. Spacers are also loaded in the empty space between the coils to make the integration of the coils stronger.

As a result, even if a large pressing force is applied to the conductor coil as the internal insert coil during molding, it is possible to prevent the relative displacement between the conductor coils.

[0015]

An embodiment of the present invention will be described with reference to the drawings.

FIG. 1 is an explanatory view of a ground coil (here, a floating coil) for a magnetic levitation type railway according to one embodiment of the present invention. FIG. 1 (a) is a front view of an internal insert coil before molding. (b) is a side view, (c) is a front view showing a state after molding, and (d) is a side view.

In these figures, 1a, 1b, 2a,
2b is a unit coil of the levitation coil, which is obtained by superposing basic coils and connecting them in series.

Here, two sets of unit coils 1a and 1b constitute one set of floating coils, and 2a and 2b constitute another set of floating coils. The unit coils (conductor coils) 1a and 1b are connected in such a manner that their winding directions are opposite to each other and are arranged in a figure-eight shape, and the unit coils 2a and 2b also have the same connection and arrangement. These unit coils 1a, 1b, 2a, 2b have a square shape with their corners rounded.

Reference numeral 3 denotes a guide terminal 3 for each of the flying coils 1 and 2.

The two sets of levitation coils 1 and 2 are arranged side by side in a state of being close to the same plane, and are collectively molded with the molding resin 12 as shown in FIG. Constitutes an internal insert coil. Here, the mold resin 12 is, for example, FRP (fiber reinforced plastic) by SMC molding.
Is used.

The internal insert coil is formed by prepreg molding in order to perform temporary molding such as baking before molding.
And the spacers 5, 6, between the unit coils 1a and 1b of the same set, between the unit coils 1a and 2a of different sets, and between the unit coils 1a and 2b of the different sets.
7, 8, 9, 10 are loaded, and the unit coils 1a, 1
All of b, 2a and 2b are integrated with the spacer by baking.

Here, the unit coils 1a, 1b, 2a, 2
The temporary molding for integration of b will be described.

Since adjacent sides of the unit coils 1a and 1b of the same set and adjacent sides of the unit coils 2a and 2b are in contact with each other, wedge-shaped spacers 5 and 6 are mounted between the other opposed Rs. I do. On the other hand, since predetermined gaps are secured between the unit coils 1a and 2a and between the sets 1b and 2b of the different sets, rectangular
And 10, and wedge-shaped spacers 7, 8 are mounted between the opposed Rs.

The spacers 5, 6, 7, 8,
9 and 10, prepreg tape (a non-woven fabric impregnated with a thermosetting resin and cured to some extent) on the surface of the spacer body 14, as shown in FIGS.
15 and wrapping them in a prepreg tape 16 to prevent the spacers from falling off.
And temporarily fixed to the unit coils 1a, 1b, 2a, 2b. By wrapping the prepreg tape 15 around each spacer body 14 as described above, it is possible to flexibly cope with a fine structure of the unit coil and irregularities on the surface.

Further, between the unit coils 1a and 1b, 2a and 2
The prepreg tape 4 for binding the coils of each other is also wound between b, 1a, 2a, and 1b, 2b.

The following must be considered when selecting and arranging the spacer body 14.

The elastic modulus is the same as or close to that of the SMC material (mold resin) 12 for molding the coil.

The linear expansion coefficient is the same as or close to that of the SMC material 12 for molding the coil.

The coils are arranged so that the thickness of the molded SMC material 12 is uniform.

Under the above conditions, the unit coils 1a, 1b, 2a, 2b with the spacers 5, 6, 7, 8, 9, 10 were wound and wound around the spacer body 14 by heating and pressing in advance during molding. As the impregnated resin (thermosetting resin) of the prepreg tape 15 oozes out and hardens, the unit coil and the spacer are baked and hardened through the thermosetting resin to be firmly integrated. Further, in the present embodiment, the unit coils are also baked with the prepreg tape 4 for binding, so that the unit coils can be integrated more firmly.

The unitary coil thus temporarily molded is then molded by SMC molding using a resin (FRP) 12 to obtain a molded coil as shown in FIG. 1 (c).

According to the present embodiment, the plurality of unit coils 1a, 1b, 2a, 2b are strongly integrated (temporarily molded) with almost no displacement on the same plane as described above. It is hardly affected by pressurization.
As shown in the figure, the thickness of the upper and lower surfaces of the internal insert coil ε ₁ ,
Molding can be performed while suppressing displacement of ε ₁ ′ and side wall thicknesses ε ₂ and ε ₂ ′.

By the way, since the levitation coil is SMC molded as a mass-produced product, it is important for production to reduce the molding time per coil.

Generally, in the SMC molding, since the molding thickness and the molding time are in a proportional relationship, the molding can be efficiently performed by eliminating the coil position deviation and making the molding coil molding thickness uniform as described above. Become.

Further, as shown in FIG.
In RP molding and the like, the greater the molding thickness, the greater the heat generated inside the mold material during curing. As a result, the residual stress in the molding material is increased, and therefore, insertion of the member into a portion where the molding thickness is increased is effective from the viewpoint of removing the residual stress.

In the above embodiment, the levitation coil has been described among the magnetic levitation type ground coils for railways. However, the invention can be applied to a general molded coil.
The mold resin may be other than FRP, and can be applied to a cast-type mold coil in addition to SMC molding. In addition, although the prepreg tape 15 is wound around the spacer body 14 for baking, the spacer body may be coated with a semi-cured thermosetting resin for temporary molding.

In the present invention, the shape and structure of the molded coil are not limited to the above-described embodiment, and various modifications can be made based on the spirit of the present invention.

[0038]

According to the present invention, the conductor coil, which is the internal insert coil in the molded coil, can be firmly integrated in advance by sintering via a spacer. By effectively suppressing the displacement between the coils and reducing the uneven thickness of the mold, insulation deterioration can be prevented. In addition, when used in a magnetic levitation type railway coil, a high magnetic levitation force is applied. An accurate molded coil can be provided.

[Brief description of the drawings]

1 (a) is a front view of an internal insert coil before molding of a magnetic levitation type railway levitation coil showing one embodiment of the present invention, FIG. 1 (b) is a side view thereof, and FIG. Front view showing the finished product after molding of the example, (d) is a side view thereof

FIGS. 2A and 2B are explanatory views showing a state where a spacer member used in the embodiment is temporarily fixed to each portion between coils.

FIG. 3 is a diagram showing the relationship between the molded thickness of a magnetic levitation type railway levitation coil and the amount of internal heat generation.

FIG. 4 (a) is a front view of an internal insert coil before molding of a magnetic levitation type railway levitation coil showing a conventional example, FIG. 4 (b) is a side view thereof, and FIG. Front view showing the finished product after molding of the floating coil,
(D) is the side view

[Explanation of symbols]

1, 2, ... floating coil, 1a, 1b, 2a, 2b ... unit coil (conductor coil), 4 ... prepreg tape for binding,
5, 6, 7, 8, 9, 10 ... spacer, 12 ... mold resin, 14 ... spacer body, 15 ... prepreg tape for hardening, 16 ... prepreg tape for temporary fixing.

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int.Cl. ⁶ , DB name) H01F 7/06 H01F 7/20

Claims (7)

(57) [Claims] A plurality of conductor coils wound a plurality of times;
In the mold coil embedded in the mold resin in a predetermined arrangement, a spacer is loaded between the conductor coils, and the spacer and the plurality of conductor coils are integrated by baking using a thermosetting resin in advance. A molded coil, wherein the molded coil is molded in a state of being formed. 2. The molded coil according to claim 1, wherein the molded resin is FRP. 3. The mold coil according to claim 1, wherein the spacer is the same member as the mold resin or a member having a similar elastic modulus and linear expansion coefficient to the mold resin. 4. The spacer according to claim 1, wherein a prepreg tape is wound around the surface of the spacer, and the spacer and the conductor are formed using a thermosetting resin impregnated in the prepreg tape. A molded coil characterized by being hardened with a coil. 5. The sintering method according to claim 1, wherein the stiffening is performed by wrapping a prepreg tape for temporarily fixing a spacer around a spacer loading portion between the conductor coils. A molded coil, characterized in that: 6. The conductive coil according to claim 1, wherein the conductive coils are bound together by a prepreg tape and are baked via the prepreg tape and the spacer. Mold coil. 7. The unit according to claim 1, wherein the conductor coil is a unit coil of a magnetic levitation type ground coil for a magnetic levitation type rail having a rounded corner. Are connected on the same plane.
The spacers are loaded between the unit coils of the same set and between the unit coils of different sets, and the two sets of unit coils are all integrated by baking. A molded coil.