JP3254852B2 - Method of coupling spool and terminal in stator integrated with connector of electromagnetic clutch - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of connecting a spool and a terminal in a stator integrated with a connector of an electromagnetic clutch.

[0002]

2. Description of the Related Art A connector-integrated stator of an electromagnetic clutch is housed in a stator housing in a state where terminals of the connector are connected to a spool around which a coil wire is wound. The connector of the connector is also formed by the molding resin at the same time. For this reason, since the terminal connected to the spool receives the pressure of the injected mold resin,
If the coupling strength between the spool and the terminal is low, the terminal comes off the spool, causing a drawback such as applying a tensile force to the coil wire connected to the terminal or disconnecting the terminal from the coil wire. Therefore, conventionally, a method of insert-molding the terminal into the spool has been proposed in order to increase the bonding strength between the spool and the terminal.

[0003]

However, when the terminal is insert-molded on the spool as described above, it is necessary to set the terminal in advance in a molding die for molding the spool. There is a problem that the cost increases. The present invention has been made based on the above circumstances, and an object of the present invention is to provide a method of coupling a spool and a terminal in a connector-integrated stator of an electromagnetic clutch that can reduce costs by reducing the number of work steps. In the offer.

[0004]

According to a first aspect of the present invention, there is provided an exciting coil formed by winding a coil wire coated with an insulating film around a spool, and electrically connected to an end of the coil wire. In a connector integrated stator of an electromagnetic clutch in which a connector having a metal terminal is integrally formed, the spool has a terminal insertion hole in which a periphery is formed of a thermoplastic resin and a rear end of the terminal is inserted. , The terminal
After the rear end is inserted into the terminal insertion hole, the coil
The terminal is energized to make connection with the wire, and the heat generated at the time of energization establishes an electrical connection between the terminal and the coil wire, and the heat generated at the time of energization generates heat at the rear end. To the terminal insertion hole
The technical means is that the connection with the spool is performed by melting the thermoplastic resin on the side .

According to a second aspect of the present invention, there is provided an exciting coil formed by winding a coil wire coated with an insulating film around a spool, and a metal terminal electrically connected to an end of the coil wire. In a connector integrated stator of an electromagnetic clutch in which a connector provided is integrally formed, the spool is:
A terminal insertion hole into which the rear end of the terminal is inserted is provided, and an adhesive that causes an adhesive reaction at a predetermined temperature or higher is applied to an outer peripheral surface of the rear end or an inner peripheral surface of the terminal insertion hole. After the terminal is inserted into the terminal insertion hole, the terminal is energized, and the terminal and the coil wire are electrically connected by heat generated when the terminal is energized, The technical means is that the heat generated at the time of the energization is transmitted to the rear end portion, and the heat is equal to or higher than the predetermined temperature and the adhesive causes an adhesive reaction to perform the connection with the spool. .

[0006]

According to the first aspect of the present invention, after the rear end of the terminal is inserted into the terminal insertion hole provided in the spool, the terminal is electrically connected to the coil wire by heat generated by energizing the terminal. Is performed. In addition, the heat generated at the time of energization is transmitted from the claw portion to the rear end portion, and by melting the thermoplastic resin around the terminal insertion hole where the rear end portion is inserted, the connection between the terminal and the spool can be firmly performed. it can.

According to a second aspect of the present invention, similarly to the first aspect, after the rear end of the terminal is inserted into the terminal insertion hole of the spool, the terminal and the coil are heated by heat generated by energizing the terminal. An electrical connection to the line is made. Also, when the heat generated during energization reaches a predetermined temperature or more at the rear end of the terminal,
The adhesive applied to the inner peripheral surface of the terminal insertion hole or the outer peripheral surface of the rear end of the terminal causes an adhesive reaction, whereby the terminal and the spool are connected.

[0008]

1 and 2 show an embodiment of an electromagnetic clutch to which the method of connecting a spool and a terminal according to the present invention is applied.
2 will be described. FIG. 1 is a sectional view of the electromagnetic clutch. The electromagnetic clutch 1 according to the present embodiment is mounted on a refrigerant compressor (not shown) of a refrigeration cycle for a vehicle, and transmits a rotating power of a stator 3 integrally formed with a connector 2 and an engine (not shown). The rotor 4 includes an armature 5 that faces the rotor 4 in the axial direction, an inner hub 7 that supports the armature 5 via a leaf spring 6, and the like.

The stator 3 includes an exciting coil 8 that generates a magnetic force when energized, and a stator housing 9 that supports the exciting coil 8. The exciting coil 8 is formed by winding a coil wire 11 (see FIGS. 12 to 17) provided with an insulating coating on a spool 10 formed of a thermoplastic resin (for example, nylon). ,
It is fixed by the mold resin 12. The method for manufacturing the stator 3 will be described in detail below.

The stator housing 9 is made of a magnetic material such as iron, and forms a magnetic path of the exciting coil 8 together with the rotor 4 and the armature 5 also made of a magnetic material. The stator housing 9 has an end face on the refrigerant compressor side (the right end face in FIG. 1) fixed to an annular arm support 13 by welding.
By being fixed to the housing 15 of the refrigerant compressor by 4, positioning in the axial direction is performed.

The rotor 4 has a U-shaped cross section (an inverted U-shaped cross section in FIG. 1) for accommodating the stator 3, and has a housing 16 of the refrigerant compressor via a bearing 16 disposed on the inner periphery thereof. 15 rotatably supported. This rotor 4
The pulley 17 is fixed to the outer peripheral portion thereof by welding or the like, and is rotated by the rotational power of the engine transmitted via a multi-stage V-belt (not shown) stretched over the pulley 17. In addition, the rotor 4 has an armature 5
The one end surface in the axial direction opposite to the above is a friction surface.

The armature 5 includes an annular inner ring 5a, and an annular outer ring 5b which is disposed around the inner ring 5a with a predetermined gap therebetween. Each of the rings 5a, 5b is made of a non-magnetic material. Rivets 18 on the leaf springs 6
Has been fixed by. The armature 5 is arranged in the axial direction so as to face the friction surface of the rotor 4, and the other end surface of each of the rings 5a and 5b (the surface facing the friction surface of the rotor 4).
Are friction surfaces.

The inner hub 7 has a plate portion 7a having a substantially triangular planar shape and a cylindrical portion 7b provided at the center of the plate portion 7a, and the cylindrical portion 7b is connected to a rotating shaft of the refrigerant compressor. 19 is fitted to the end of
It is fixed by. The above-mentioned leaf spring 6 is used for the rivet 2.
1 is fixed to the plate portion 7a of the inner hub 7. Therefore, the armature 5, the leaf spring 6, and the inner hub 7 rotate integrally with the rotating shaft 19 of the refrigerant compressor.

The plate spring 6 urges the armature 5 in a direction away from the rotor 4 (to the left in FIG. 1) so as to cancel the frictional engagement between the armature 5 and the rotor 4 when the excitation coil 8 is de-energized. . A rubber stopper 22 for positioning the armature 5 urged by the leaf spring 6 when the excitation coil 8 is turned off is attached to the plate portion 7 a of the inner hub 7.

On the inner periphery of the armature 5 (the inner periphery of the inner ring 5a), a rubber-made suction noise reducing member 23 is arranged to reduce the suction noise generated when the armature 5 is sucked by the rotor 4. ing. This suction noise reducing member 23
Is supported by a metal support member 24, and one end face side is pressed by the leaf spring 6. The support member 24 is fixed to the plate portion 7a of the inner hub 7 by rivets 21 together with the leaf spring 6.

Here, a method of manufacturing the stator 3 will be described with reference to FIG.
This will be described with reference to FIG. First, a metal (for example, copper alloy) terminal 25 is inserted (press-fitted) into a terminal insertion hole 10a (see FIG. 2) formed in the spool 10 (FIG. 3 to FIG. 3).
6). As shown in FIG. 7, the terminal insertion hole 10a has a rectangular cross section and is provided at two predetermined positions in the circumferential direction of the spool 10.

As shown in FIGS. 8 to 11, the terminal 25 has a claw 25a for caulking and fixing the ends 11a and 11b of the coil wire 11, and the terminal 25 is inserted into the terminal insertion hole 10a. On both sides of the end portion 25b (the right end portion in FIG. 8), serrated protrusions 25c for preventing the terminal 25 from coming out of the terminal insertion hole 10a are provided. Further, two constricted portions 25d for bending the terminal 25 into a predetermined shape are provided on the tip side from the claw portion 25a.

After inserting the terminal 25 into the terminal insertion hole 10a, the coil wire 11 is wound around the spool 10, and both ends 11a and 11a of the coil wire 11 at the beginning and end of the winding are wound.
b is fixed by caulking with the claw portion 25a of the terminal 25 (FIG. 12).
And FIG. 13). The end 11a of this coil wire 11
FIG. 14 shows a state in which 11b is crimped with the claw portion 25a of the terminal 25.
To FIG.

Subsequently, by energizing while pressing the electrode 26 against the claw portion 25a, the insulating film of the coil wire 11 is broken by heat generated at the time of energization, and the electrical connection between the coil wire 11 and the terminal 25 is performed. (See FIG. 17). The heat generated during the energization is transmitted to the rear end 25b of the terminal 25, so that the resin around the terminal insertion hole 10a of the spool 10 melts. Thereafter, the termination of the current to the electrode 26 causes the terminal 2
When the temperature of the rear end portion 25b of the spool 5 decreases, the melted resin comes into close contact with the terminal 25 so as to wrap around the terminal 25.
The connection between 0 and the terminal 25 is firmly performed.

Excitation coil 8 wound on spool 10
After being housed in the stator housing 9 as shown in FIG. 18, the terminal 25 is bent into a predetermined shape at the constricted portion 25d as shown in FIG. At this time, a cylindrical coupler 27 for protecting the terminal 25 with the mold resin 12 is also molded at the same time to form the connector 2 (see FIGS. 20 to 22).

[Modification] In order to further strengthen the connection between the spool 10 and the terminal 25, as shown in FIGS. 23 and 24, a hole 25e is provided in a rear end portion 25b inserted into the terminal insertion hole 10a. May be. Also, instead of the hole 25e,
Protrusions and irregularities may be provided on the surface of the rear end portion 25b. The cross-sectional shape of the terminal insertion hole 10a of the spool 10 is not limited to the rectangular shape shown in the present embodiment.
As shown in (1), the protrusion 10b may be provided partially on the inner peripheral side so that the resin is easily melted by the heat transfer from the terminal 25.

The spool 10 does not need to be entirely formed of a thermoplastic resin, but may be formed of a thermoplastic resin only at a portion where the terminal insertion hole 10a is formed, and may be formed of a thermosetting resin for the other portions. Further, an adhesive (for example, an epoxy-based adhesive) that causes an adhesive reaction at a high temperature may be applied to the inner peripheral surface of the terminal insertion hole 10a of the spool 10 or the outer peripheral surface of the rear end 25b of the terminal 25. In this case, the heat generated when the electrode 26 is energized is transmitted to the rear end portion 25b of the terminal 25, and the adhesive causes an adhesive reaction.
5 is performed. In this embodiment, the spool 10
Although the step of winding the coil wire 11 after inserting the terminal 25 into the terminal insertion hole 10a of FIG. 1 has been described, the terminal 25 is inserted into the terminal insertion hole 10a after winding the coil wire 11 on the spool 10. May be.

[0023]

According to the present invention, the resin which forms the terminal insertion hole of the spool is melted by utilizing the heat generated by energizing the electrode when the coil wire is connected to the terminal, or an adhesive reaction of the adhesive occurs. By doing so, the connection between the spool and the terminal can be firmly performed due to the temperature drop after the end of energization. Therefore, unlike the related art, there is no need to insert-mold the terminal on the spool, and the cost can be reduced by reducing the number of working steps.

[Brief description of the drawings]

FIG. 1 is a sectional view of an electromagnetic clutch.

FIG. 2 is a half sectional view of a spool.

FIG. 3 is a sectional view showing a state where a terminal is inserted into a terminal insertion hole of a spool.

FIG. 4 is an enlarged view showing an inserted state of a terminal.

FIG. 5 is a side sectional view showing a state where a terminal is inserted.

FIG. 6 is a view as viewed from A in FIG. 4;

FIG. 7 is a cross-sectional view showing an opening shape of a terminal insertion hole.

FIG. 8 is a plan view of a terminal.

FIG. 9 is a side view of the terminal.

FIG. 10 is a view as viewed from B in FIG. 9;

FIG. 11 is a rear plan view of the terminal.

FIG. 12 is a sectional view showing a state where a coil wire is wound around a spool.

FIG. 13 is a view as viewed from C in FIG. 12;

FIG. 14 is a plan view showing a state in which the end of the coil wire is fixed by caulking with a claw of a terminal.

FIG. 15 is a view as viewed in the direction D of FIG. 14;

FIG. 16 is a view as viewed from E in FIG. 14;

FIG. 17 is a diagram showing a state in which an end of a coil wire is electrically connected to a terminal.

FIG. 18 is a cross-sectional view showing a state in which an exciting coil wound on a spool is housed in a stator housing.

FIG. 19 is a sectional view showing a state in which the terminal is bent into a predetermined shape.

FIG. 20 is a cross-sectional view of a stator in which a connector is integrally formed of a mold resin.

FIG. 21 is a diagram viewed from F in FIG. 20;

FIG. 22 is a G view of FIG. 20;

FIG. 23 is a plan view of a terminal (modification).

FIG. 24 is a rear plan view of a terminal (modification).

FIG. 25 is a front view showing an opening shape of a terminal insertion hole (modification).

26 is a sectional view taken along line HH of FIG. 25 (modification).

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Electromagnetic clutch 2 Connector 3 Stator 8 Exciting coil 10 Spool 10a Terminal insertion hole 11 Coil wire 25 Terminal 25b Rear end

Continuation of the front page (56) References JP-A-61-27316 (JP, A) JP-A-2-59327 (JP, U) JP-A-61-194832 (JP, U) (58) Fields investigated (Int) .Cl. ⁷ , DB name) F16D 27/10

Claims (2)

(57) [Claims] An electromagnetic coil having an exciting coil formed by winding a coil wire coated with an insulating film around a spool, and a connector having a metal terminal electrically connected to an end of the coil wire. In the connector integrated stator of a clutch, the spool is formed of a thermoplastic resin at a periphery thereof, and has a terminal insertion hole into which a rear end of the terminal is inserted. After being inserted into the hole, the terminal is energized to perform connection with the coil wire, and the terminal and the coil wire are electrically connected by heat generated at the time of the energization, and at the time of energization. transmitted heat generated to the rear end portion, said by the heat
A method of joining a spool and a terminal in a connector-integrated stator of an electromagnetic clutch, wherein the joining with the spool is performed by melting a thermoplastic resin around the terminal insertion hole . 2. An electromagnetic device comprising: an exciting coil formed by winding a coil wire coated with an insulating film around a spool; and a connector integrally formed with a metal terminal electrically connected to an end of the coil wire. In the connector integrated stator of a clutch, the spool is provided with a terminal insertion hole into which a rear end of the terminal is inserted, and an outer peripheral surface of the rear end or an inner peripheral surface of the terminal insertion hole has a predetermined temperature. An adhesive that causes an adhesive reaction is applied as described above, and the terminal is energized to the terminal after the rear end is inserted into the terminal insertion hole, and the terminal and the terminal are heated by heat generated at the time of energization. Electrical connection with the coil wire is performed, and the heat generated at the time of the energization is transmitted to the rear end, and the heat becomes equal to or higher than the predetermined temperature and the adhesive causes an adhesive reaction, thereby causing the adhesive to react with the spool. The join is done Coupling method between the spool and the terminals in the connector piece stator of the electromagnetic clutch, characterized in that it is.