JP3093301B2 - Resin molded coil and manufacturing method thereof - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[Object of the Invention]

[0002]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin molded coil in which a plurality of unit coils are arranged at predetermined intervals in an axial direction and molded with a molding resin, and a method of manufacturing the same.

[0003]

2. Description of the Related Art Conventionally, when manufacturing a resin mold coil of this type, for example, as shown in FIG. 4, a resin spacer 3 is interposed between each unit coil 2 disposed in an inner mold 1. The unit coils 2 are fitted so that the intervals between the unit coils 2 are kept constant, and positioning in the axial direction is performed. Further, each spacer 3 is formed in an L-shaped cross section, and a part of the spacer 3 is fitted between the inner peripheral surface of the unit coil 2 and the inner die 1 so that the radial direction of each unit coil 2 Is determined.
Under such positioning by the L-shaped spacer 3, each unit coil 2 is molded together with the spacer 3 by molding resin to produce a resin molded coil.

[0004]

According to the above-mentioned conventional manufacturing method, the contact portion between the spacer 3 and the unit coil 2 is
Since the mold resin does not flow, the two are not bonded,
Moreover, since the adhesive strength between the spacer 3 and the mold resin is not so high, the mold strength around the spacer 3 is relatively reduced. Further, since the molding resin does not flow into the contact portion between the inner mold 1 and the spacer 3, the spacer 3 is exposed on the inner peripheral side of the resin molded coil, and the decrease in the mold strength on the inner peripheral side is large. Tended to be. For this reason, due to the repetition of the vibration and the vertical movement of the temperature during the operation, the mold resin is likely to peel or crack in the peripheral portion of the spacer 3 where the mold strength is weak, and the life of the dielectric strength is short. there were.

[0005] The present invention has been made in view of such circumstances, and the object thereof is to improve the mold strength, to prevent the mold resin from being easily peeled or cracked, and to provide an excellent dielectric strength for a long period of time. An object of the present invention is to provide a resin molded coil that can be sustained and a method of manufacturing the same.

[Configuration of the Invention]

[0007]

According to the present invention, there is provided a resin molded coil formed by molding a plurality of unit coils arranged at predetermined intervals in an axial direction with a molding resin. Spacer that regulates
It is composed of a resin base material and prepregs addressed to both surfaces thereof and is embedded in the mold resin, and two prepregs are arranged along the inner peripheral surface of each unit coil, and between these two prepregs. It is configured to be embedded in the mold resin together with the interposed distance regulating member.

In order to manufacture such a resin-molded coil, the manufacturing method of the present invention comprises a step of winding two prepregs along an outer peripheral surface of an inner mold, and a step of winding a plurality of prepregs on the outer peripheral side of these two prepregs. Providing a unit coil with a spacer formed by inserting a resin base material in a U-shaped prepreg between the unit coils; and providing a unit coil between two prepregs on the inner peripheral side of the unit coil. A step of inserting a rod-shaped interval regulating member in the axial direction at a plurality of positions to radially position each of the unit coils, and mounting an outer mold on the inner mold, injecting a mold resin into these molds, and molding. And a molding step.

[0009]

According to the resin molded coil of the present invention, since the prepreg is sandwiched between the resin base material which is a component of the spacer for regulating the interval between the unit coils and the unit coil, The resin base and the unit coil are firmly bonded by the prepreg. In addition, since the contact area between the resin base material and the mold resin is significantly reduced due to the presence of the prepreg as compared with the conventional L-shaped spacer, a decrease in the mold strength due to the adhesion state of the portion is small and can be almost ignored. About. Furthermore, since the two prepregs are embedded on the inner peripheral side of the resin mold coil together with the gap regulating member interposed therebetween, the gap regulating member and the inner peripheral surface of each unit coil are firmly formed by the prepreg. While being adhered, the inner peripheral surface of the resin mold coil is reinforced by the prepreg.

Further, according to the manufacturing method of the present invention, the spacer formed by inserting the resin base material into the U-shaped prepreg is fitted (pushed) between the unit coils. The prepregs on the upper and lower surfaces of the base material do not shift and move, and these can be pushed together, and the pushing operation can be performed extremely easily. In addition, since a rod-shaped interval regulating member is inserted in the axial direction between two prepregs set in advance on the inner peripheral side of each unit coil, the radial positioning of each unit coil is performed. When compared with the case where the gap regulating member is inserted into the inner circumference of the unit coil at the same time, excessive force does not work at the time of insertion, the insertion work is easy, and the prepreg is not deformed or buckled, In general, the positioning of each unit coil in the radial direction is easy and reliable.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be described below with reference to FIGS. The resin mold coil molded by the manufacturing method of this embodiment has a plurality of unit coils 11 arranged at predetermined intervals in the axial direction. Then, a spacer 12 for regulating the interval between the unit coils 11 is provided.
Is composed of a prepreg 13 formed in a U-shape and a resin base material 14 inserted into the prepreg 13. As shown in FIG. 2, for example, four spacers 12 are arranged between each unit coil 11.

Here, the prepreg 13 of the spacer 12
As shown in FIG. 3, a semi-cured resin is impregnated in a glass cloth 15 woven into a mesh, and the impregnated resin is the same epoxy resin as the mold resin (however, a semi-cured resin). It is preferable to employ Similarly, it is preferable that the resin base 14 is also formed of the same epoxy resin as the mold resin.

Further, as shown in FIG.
The two prepregs 16 and 17 are arranged along the inner peripheral surface of the prepreg, and a rod-shaped interval regulating member 18 is inserted in the axial direction at, for example, four places between the prepregs 16 and 17. These prepregs 16 and 17 are axially dimensioned so as to collectively cover the inner peripheral surfaces of all the unit coils 11.
8, the thickness of the insulating resin layer on the inner peripheral side of each unit coil 11 is regulated to be uniform. Therefore, at the time of molding, the inner prepreg 16 is arranged along the molding surface of the inner mold 19. These prepregs 16 and 17 are also the prepreg 13 of the spacer 12 described above.
, And the interval regulating member 18 is also
It is preferable to use the same epoxy resin as the mold resin.

The unit coils 11, the spacers 12, the prepregs 16 and 17 and the space regulating member 1 arranged in this manner.
Numeral 8 is integrated by being molded with an insulating resin such as an epoxy resin.

Next, a method of manufacturing the resin molded coil having the above-described configuration will be described. First, as shown in FIG.
The two prepregs 16 and 17 are wound once each along the entire outer peripheral surface of. Next, a plurality of unit coils 11 wound and formed in advance by a winding machine (not shown) are removed from the winding machine, and the two prepregs 16 and 1 are removed.
7 is temporarily stacked on the outer peripheral side. At this time, each unit coil 1
A temporary comb-shaped spacer (not shown) is fitted between the unit coils 1 so that the interval between the unit coils 11 is maintained at a predetermined value.

In this manner, each unit coil 11 is connected to the inner mold 1
After setting to 9, the spacers 12 formed by inserting the resin base material 14 in the U-shaped prepreg 13 in advance, for example, four spacers 12 are fitted between the unit coils 11. Thus, the intervals between the unit coils 11 are kept uniform, and the unit coils 11 are positioned in the axial direction. Then, after the work of fitting the spacers 12 has been completed for all the unit coils 11, the above-mentioned temporary comb-shaped spacer is removed.

Thereafter, a bar-shaped interval regulating member 18 is inserted in the axial direction at, for example, four places between the two prepregs 16 and 17 arranged on the inner peripheral side of the unit coil 11. As a result, the interval between the two prepregs 16 and 17 is expanded, so that the inner prepreg 16 is in close contact with the inner mold 19 and the outer prepreg 17 is in close contact with the inner peripheral surface of each unit coil 11. 11 is positioned in the radial direction, and each unit coil 11 is fixed to the inner mold 19.

Thereafter, outer molds (not shown) are attached to the inner mold 19, and a raw material liquid of an insulating mold resin (for example, epoxy resin) is injected into these molds and molded. At the time of the molding, when the raw material liquid of the molding resin reacts with the curing agent and cures, at the same time, each prepreg 13, 1
6, 17 semi-cured impregnated resin is also cured to form a resin base material 1
4 and the unit coil 11 are firmly adhered, and the spacing regulating members 18 are firmly adhered to the inner peripheral surface of the unit coil 11. Further, at the contact portions between the respective prepregs 13, 16, 17 and the mold resin, the two are firmly joined and integrated.

After the mold resin is cured, the mold is opened and the molded product of the unit coil 11 (resin molded coil) is taken out from the inner mold 19, thereby completing the resin molded coil manufacturing process.

According to the resin molded coil manufactured in this manner, the resin base material 14 and the unit coil 1 which are constituent elements of the spacer 12 for regulating the interval between the unit coils 11 are formed.
Since the prepreg 13 is sandwiched between the prepreg 13 and the resin coil 1, the resin base 14 and the unit coil 11 can be firmly bonded to each other by the prepreg 13. Moreover, the resin substrate 1
The contact area between the mold resin 4 and the mold resin is also significantly reduced due to the presence of the prepreg 13 as compared with the conventional L-shaped spacer 3, so that the decrease in mold strength due to the adhesion state of the portion is small and almost negligible. . Thereby, the strength of the mold around each spacer 12 can be greatly improved as compared with the conventional case.

Further, also on the inner peripheral side of the resin mold coil,
Since the two prepregs 16 and 17 are buried together with the gap regulating member 18 interposed therebetween, the gap regulating member 18 and the inner peripheral surface of each unit coil 11 are connected to the prepreg 1.
7 allows the adhesive to be more firmly attached, and the entire inner peripheral surface of the resin mold coil can be effectively reinforced by the prepreg 16. Of course, a uniform insulating resin layer can be formed on the inner peripheral side of each unit coil 11 by the positioning function of the two prepregs 16 and 17 and the interval regulating member 18. Thereby, the mold strength on the inner peripheral side of the resin mold coil can be significantly improved as compared with the related art.

In this way, since the mold strength of the portion which was considered to be weak in the conventional structure can be greatly improved, even if the vibration or the temperature is repeatedly moved up and down during operation, peeling or cracking of the mold resin occurs. It hardly occurs, and excellent insulation strength can be maintained for a long period of time, and insulation quality can be greatly improved.

According to the manufacturing method of this embodiment,
The spacer 12 formed by inserting the resin base material 14 into the U-shaped prepreg 13 is inserted (pressed) between the unit coils 11 in advance. The reason for this is as follows. is there.

That is, if the resin base material 14 is pushed into the prepreg 13 inserted between the unit coils 11 in advance, there is a disadvantage that the prepreg 13 is shifted when the resin base material 14 is pushed. Further, when the prepreg 13 is divided into two sheets, even if these two prepregs are pushed between the unit coils 11 in a state of being overlapped with the resin base material 14, the prepregs may shift due to the insertion resistance. There is a risk of deformation and buckling, which is also troublesome.

In this regard, according to the manufacturing method of the present embodiment, the prepreg 13 on the upper and lower surfaces of the resin substrate 14 is integrated by forming the prepreg 13 in a U-shape.
Since the spacers 12 formed by inserting the resin base material 14 in the U-shaped prepreg 13 in advance are inserted (pushed) between the unit coils 11, the prepregs on the upper and lower surfaces of the resin base material 14 at the time of the pressing are formed. 13 can be pushed in integrally without shifting, and the pushing operation can be performed extremely easily. In addition, the resin base material 14 serves as a core material for maintaining the shape of the U-shaped prepreg 13, and has an advantage that deformation and buckling of the prepreg 13 at the time of pushing can be prevented. Also, when the resin base material 14 is inserted into the U-shaped prepreg 13, since the prepreg 13 has flexibility, the work of inserting the resin base material 14 is also easy.

In addition, a rod-shaped interval regulating member 18 is inserted in the axial direction between the two prepregs 16 and 17 set in advance on the inner peripheral side of each unit coil 11 to position each unit coil 11 in the radial direction. Therefore, as compared with the case where these two prepregs 16 and 17 and the space regulating member 18 are simultaneously inserted into the inner peripheral side of the unit coil 11, an excessive resistance does not work at the time of insertion and the insertion work is easy. Along with
The deformation and buckling of the prepregs 16 and 17 are not caused, and the positioning of the unit coils 11 in the radial direction is generally easy and reliable.

In this embodiment, four spacers 12 are fitted between the unit coils 11, but two or five spacers 12 may be used. Similarly, the unit coil 11
The number of the interval regulating members 18 to be inserted between the two prepregs 16 and 17 arranged on the inner peripheral side is not limited to four.
The number may be five or more.

[0028]

As is apparent from the above description, according to the resin molded coil of the present invention, the prepreg is provided between the resin base material which is a component of the spacer for regulating the interval between the unit coils and the unit coil. Is sandwiched, so that the resin base material and the unit coil can be firmly bonded by the prepreg. In addition, since the two prepregs are buried on the inner peripheral side of the resin molded coil together with the space regulating member, the entire inner peripheral surface of the resin molded coil can be effectively reinforced by the prepreg. For this reason, the mold strength against repetition of vibration and temperature up and down during operation can be greatly improved, and peeling and cracking of the mold resin are less likely to occur, and excellent dielectric strength can be maintained for a long period of time.

According to the manufacturing method of the present invention, the spacer formed by inserting the resin base material into the U-shaped prepreg is fitted (pushed) between the unit coils. The prepregs on the upper and lower surfaces of the base material do not shift and move, and these can be pushed together, and the pushing operation can be performed extremely easily. In addition, since a rod-shaped interval regulating member is inserted in the axial direction between two prepregs set in advance on the inner peripheral side of each unit coil to position each unit coil in the radial direction, it is impossible to insert the unit coil at the time of insertion. The resistance work does not work, and the insertion work (the work of positioning each unit coil in the radial direction) becomes easy and reliable.

[Brief description of the drawings]

FIG. 1 is a longitudinal sectional view of a main part showing one embodiment of the present invention.

FIG. 2 is a plan view showing a state before molding.

FIG. 3 is an enlarged view of a glass cloth constituting a prepreg.

FIG. 4 is a longitudinal sectional view of a main part showing a conventional example.

[Explanation of symbols]

11 is a unit coil, 12 is a spacer, 13 is a prepreg, 14 is a resin substrate, 15 is a glass cloth, 16 and 1
7 is a prepreg, 18 is an interval regulating member, and 19 is an inner mold.

Claims (2)

(57) [Claims] 1. A resin molded coil formed by molding a plurality of unit coils arranged at predetermined intervals in an axial direction with a molding resin, wherein a spacer for regulating the interval between the unit coils is formed by a resin base material. A prepreg addressed to both surfaces thereof, buried in a mold resin, and two prepregs arranged along the inner peripheral surface of each unit coil, and a space interposed between the two prepregs. A resin molded coil embedded in the molding resin together with a regulating member. 2. A step of winding two prepregs along an outer peripheral surface of an inner die, a plurality of unit coils on an outer peripheral side of the two prepregs, and a U-shaped prepreg between the unit coils. A step of providing a spacer formed by inserting a resin base material therein, and inserting a rod-shaped interval regulating member in the axial direction at a plurality of locations between two prepregs on the inner peripheral side of each unit coil. A method for manufacturing a resin mold coil, comprising: a step of positioning each unit coil in a radial direction; and a step of mounting an outer mold on the inner mold, injecting a mold resin into these molds, and molding.