JP3407666B2 - Solenoid coil assembly and method of manufacturing the same - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a solenoid coil assembly and a manufacturing method thereof, and more particularly to a solenoid coil assembly suitable for driving a linear solenoid valve and a manufacturing method thereof.

[0002]

2. Description of the Related Art Conventionally, as shown in FIGS. 6 and 7, in a solenoid coil assembly of this type, a connector portion 1 for electrically connecting the coil to the outside has a flange portion 2a of a core 2.
Was located on the outer diameter side of the.

Further, as shown in FIG. 7, the space between the connector portion 1 and the flange portion 5a of the bobbin 5 on which the connector portion 1 is provided is utilized on the left side of the flange portion 2a of the core 2 in the figure. It was done in shape.

[0004]

In such a structure, the solenoid coil assembly 3 is formed by the entire thickness of the connector portion 1.
The maximum dimension T in the radial direction becomes large, and it is not possible to sufficiently meet the recent demand for miniaturization of equipment.

Further, due to the connection space between the connector portion 1 and the flange portion 5a of the bobbin 5 in which the connector portion 1 is provided, the effective winding length in the axial direction of the core (direction of arrow AB) is shortened, and that much. There is a disadvantage that the electromagnetic force that can be exerted by the solenoid coil assembly is reduced.
Further, in order to make up for the shortage of the effective winding length, the winding diameter of the exciting coil 33 must be made large, and the maximum size T in the radial direction of the solenoid coil assembly 3 is correspondingly large. .

In view of the above circumstances, the present invention provides a solenoid coil assembly capable of further miniaturizing the solenoid coil assembly and exerting a strong electromagnetic force, and a manufacturing method thereof. To aim.

[0007]

The present invention according to claim 1 (see FIG. 1) includes a core (25) having a tubular portion (25e) and a flange portion (25f) provided on one of the tubular portions. )
And a bobbin (26) having a coil winding portion (26a) fitted in the tubular portion, wherein an exciting coil (33) is wound around the coil winding portion (26a) of the bobbin. In the solenoid coil assembly (29) in which the connector portion (32) having the terminal (32c) is provided on the bobbin (26), a concave connector mounting portion (25g) is formed on the flange portion of the core. The bobbin connector part (32) is installed in the connector housing part so that at least a part of the connector part (32) is housed in the flange part (25f).

According to a second aspect of the present invention (see FIG. 4), the coil winding portion (26a) of the bobbin (26) has a thin wall, and the tubular portion (25e) of the core (25) has the above-mentioned structure. With the coil winding portion (26a) of the bobbin fitted,
By winding the exciting coil (33) around the coil winding portion, the coil winding portion (26a) is deformed and the bobbin (26) is integrally fixed to the core (25). The solenoid coil assembly according to claim 1.

According to a third aspect of the present invention (see FIG. 2), the connector accommodating portion (25g) penetrates the flange portion (25f) in the axial direction of the core (25) to form the tubular portion. The solenoid coil assembly according to claim 1 or 2, wherein the groove is a tapered hole that narrows toward (25e).

The present invention according to claim 4 (see FIG. 3) is the solenoid coil assembly according to claim 3, wherein the groove (25g) is formed with an unevenness (25i).

According to a fifth aspect of the present invention (see FIGS. 2 and 4), a positioning hole (25b) is formed through the flange portion (25f) of the core (25), and the bobbin ( 26) is engaged, and a taper portion (25c) having a large diameter on the opposite side surface side is formed at least on the side surface (25a) side opposite to the tubular portion (25e) of the positioning hole. The solenoid coil assembly according to any one of 1 to 4.

The present invention according to claim 6 (see FIG. 1) is characterized in that the solenoid coil assembly (29) is constructed as a linear solenoid type solenoid coil assembly. Located in the solenoid coil assembly.

The present invention according to claim 7 (see FIGS. 1 and 5) uses a core (25) having a tubular portion (25e) and a flange portion (25f) provided on one of the tubular portions, A concave connector housing portion (25g) and a positioning hole (25b) are formed in the flange portion (25f) of the core,
Connector part (32) and tubular coil winding part (26a)
The core (25) is inserted into the bobbin (26) provided with the coil, and the tubular portion (25e) of the core is inserted into the coil winding portion (26a) of the bobbin (26), and the positioning hole (25b) The bobbin is engaged with the bobbin to prevent relative rotation of the bobbin and the core, and at least a part of the connector part (32) is housed in the connector housing part (25g). In this state, the bobbin (26) and the core (25) are integrally rotated, the exciting coil (33) is wound around the coil winding portion (26a) of the bobbin, and the winding of the exciting coil is completed. (25) and the bobbin (26) are integrated by resin formation, which is a method for manufacturing a solenoid coil assembly.

The numbers in parentheses are for convenience of showing the corresponding elements in the drawings, and therefore the present description is not limited to the description in the drawings. The same applies to the following actions and effects of the invention.

[Operation] With the above structure, the present invention is
At least a part of the connector portion (32) acts so as to be housed in the flange portion (25f) of the core (25).

[0016]

According to the present invention of claim 1, a concave connector accommodating portion (25g) is formed in the flange portion of the core, and the connector accommodating portion (3) of the bobbin is formed in the connector accommodating portion.
2) at least part of which is the flange (25f)
The bobbin (26) has a connector portion (32), which is installed in a form such that the bobbin (26) has a flange portion (25).
f) Enter the inside of the tubular part (25e) of the core (25)
You can prevent it from sticking out. Therefore, the exciting coil (33) can be wound in such a manner that the length of the tubular portion (25e) of the core (25) in the left-right direction in the figure is effectively used. The size of the exciting coil (33) in the radial direction can be reduced, and a larger number of turns can be obtained with the winding completion size of the same radius, and a stronger electromagnetic force can be exerted. It is possible to provide an assembly.

Further, at least a part of the connector portion (32) is a flange (25f) connector housing portion (25g).
Since it is housed inside and the radial dimension of the exciting coil (33) can be reduced, the maximum radial dimension T of the entire solenoid coil assembly (29) can be reduced, thus reducing the size of the device. Can contribute to the realization.

According to the second aspect of the present invention, since the winding portion (26a) of the bobbin (26) is thin, the bobbin (26) is integrally fixed to the core (25) by the winding force of the exciting coil. The wall thickness of the bobbin winding portion (26a) can be reduced, and the solenoid coil assembly can be downsized accordingly.

According to the third aspect of the present invention, when the resin is secondarily molded, the resin is filled into the gap formed between the tapered connector accommodating portion and the connector portion (32). Therefore, the bobbin (26) is surely integrated with the core (25) through the connector portion (32), and the filled resin acts as a wedge, so that the exciting coil (33) is wound. It is possible to prevent the bobbin (26) from falling out of the core (25) due to some impact, and it is possible to provide a highly reliable solenoid coil assembly.

According to the present invention of claim 4, unevenness (2
5i) makes it possible to further improve the adhesion between the resin and the core (25) during the secondary formation.

According to the present invention of claim 5, when the exciting coil (33) is wound by the positioning hole (25b),
The relative rotation between the core (25) and the bobbin (26) can be prevented, and the positioning hole (25b) can also be used for positioning the core with respect to the winding machine, thereby improving the production efficiency. Can be done. Further, the taper portion (25c) can be utilized also as a bobbin removal stopper by embedding a resin in the secondary formation.

According to the present invention of claim 6, since it is applied to a linear solenoid type solenoid coil assembly,
Where a valve body of an automatic transmission is required to be further compacted, a linear solenoid having the compacted solenoid coil assembly is applied to reduce the overall size of the device such as the automatic transmission. Can be planned.

According to the present invention of claim 7, claim 1
In addition to the effect described in, the positioning hole (25b)
When the exciting coil (33) is wound, relative rotation between the core (25) and the bobbin (26) can be prevented, and accurate winding work can be performed.

[0024]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a cross-sectional view showing an example of the linear solenoid valve 6, and the linear solenoid valve 6 drives the pressure regulating valve section 7 and a plunger 37 or the like for a constant exciting current value regardless of a moving stroke thereof. It has an electromagnet portion 9 which constitutes a linear solenoid having a characteristic capable of exerting a force. Further, the pressure regulating valve portion 7 is provided with a valve sleeve 10 and a spool 11. The valve sleeve 10 has a hole 13 for accommodating a spring 12 and an adjusting bolt 28 described later in the axial direction of the valve sleeve 10, and subsequently the spool 11. A guide hole 15 for slidingly guiding is formed so as to penetrate therethrough. A drain port 16, an output port 17, and a supply port 19 which are opened in the radial direction are sequentially formed on the outer peripheral portion of the valve sleeve 10 corresponding to the guide hole 15, and the guide hole portion of these ports has an annular shape. Each groove is formed. A triangular notch 19a is formed in the supply port 19 portion, and the notch 19a adjusts the supply hydraulic pressure to a predetermined output pressure by adjusting the throttle amount in a spool described later, and at the same time the hydraulic pressure It is for suppressing vibration. Further, the reference numeral 20 forms a feedback pressure chamber, which is closed without communicating with the oil passage.

The spool 11 has two land portions 21 and 22 which are in sliding contact with the guide hole 15 portion.
The land portion 21 includes the output port 17 and the drain port 1.
6 restricts the output pressure of the output port 17 from exceeding a predetermined pressure, and the land portion 22 restricts the supply port 19 and the output port 17 to communicate with each other to supply the power from the supply port 19. The pressure is adjusted to a pressure corresponding to the position of the spool 11 and output as output pressure from the output port 17.
Further, the spool 11 has a spring holding projection 11a formed at one end thereof.

A screw 13a is formed at the rear end portion of the hole 13 in the valve sleeve 10, and an adjusting bolt 28 is screwed into the screw 13a. The coil spring 12 is contracted between the adjusting bolt 28 and the spring holding protrusion 11a of the spool, and the urging force of the spring 12 is adjusted by rotating the adjusting bolt 28. Furthermore, a rotation stopper 23 is provided at the rear end of the valve sleeve 10, and the adjustment bolt 28 is fixed at a predetermined position by the rotation stopper 23. Also,
The front end side of the valve sleeve 10 is a flange portion 10a that expands in the outer diameter direction, and the pressure regulating valve portion 7 is fixed to the electromagnet portion 9 which is a linear solenoid by the flange portion 10a.

On the other hand, the electromagnet portion 9 is composed of the cylindrical core 2
5. A solenoid coil assembly 29 including a bobbin 26 arranged on the outer peripheral portion of the core, an exciting coil 33 wound on the bobbin 26, a connector portion 32 provided on the outer peripheral portion of the bobbin, and the like. As shown in FIG. 2, the core 25 has a cylindrical tubular portion 25e (hereinafter referred to as a coil winding portion) and a flange portion 25f formed at the lower end of FIG. 2 (a). . On the outer peripheral portion of the flange portion 25f, a connector mounting portion 25g as a connector accommodating portion narrows in width from the core side surface 25a toward the coil winding portion 25e (that is, the arrow A, which is the core axial direction, The flange portion 25f is formed with positioning holes 25b, 25b at 180 ° pitch in the core axial direction. Core side surface (side surface opposite to coil winding portion) 25a of each positioning hole 25b
A tapered portion 25c having a large diameter on the side surface side is formed on the.

A bobbin 26 is inserted and mounted on the coil winding portion 25e of the core 25 by a cylindrical coil winding portion 26a as shown in FIG. 5 (b). The coil winding portion 26 is made of a thin wall
Collar portions 26b and 26c are formed in an annular shape on both sides of a. On the left side of the collar portion 26c in FIG. 5 (a), positioning protrusions 26d, 26d protruding at a 180 ° pitch are provided.
5, each of the positioning holes 25b is provided with its tip fitted, and the tip of the protrusion 26d is, as shown in FIG.
Within each positioning hole 25b, the holes 25b are engaged with each other without penetrating the hole 25b and staying at an intermediate position. As a result, the vicinity of the tapered portion 25c on the core side surface 25a side of each positioning hole 25b is hollow.

Further, as shown in FIG. 5A, a connector base 32a of the connector portion 32 is integrally resin-formed on the collar portion 26c, and the connector base 32a is attached to the connector mounting portion 25g of the core 25. , As shown in FIG. A connector main body 32b including a connector base 32a and a terminal 32c are mounted on the upper portion of the connector mounting portion 25g in the drawing, and a cover 32d formed integrally with the connector main body 32b is provided around the terminal 32c. .

An exciting coil 33 is wound around the coil winding portion 26a of the bobbin 26, and both ends of the exciting coil 33 are connected to the above-mentioned terminals 32c. Excitation coil 3
The outer peripheral portion of 3 is covered with a cover 35 integrally formed with the connector body 32b and the cover 32d described above by an insulating resin.

This cylindrical core 25, a bobbin 26 arranged on the outer peripheral portion of the core, an exciting coil 33 wound around the bobbin 26, a connector portion 32 provided on the outer peripheral portion of the bobbin, etc. As shown in FIG. 1, a solenoid coil assembly 29 integrally covered with an insulating resin forming 32d, 35, etc. has a cylindrical case 39.
A cap 40 is caulked and fixed to the front end surface of the case 39, and the case 39 and the cap 40 seal the electromagnet portion 9. On the other hand, on the pressure regulating valve section 7 side of the case 39, a step portion 39a is formed and a caulking portion 39b is formed. With the flange portion 25f of the core 25 abutting on the step portion 39a, the valve sleeve 10 By sandwiching the flange portion 10a and the flange portion 25f of the core 25 with the caulking portion 39b,
The pressure regulating valve portion 7 and the electromagnet portion 9 are integrally connected and fixed.

On the other hand, the core 25 has a through hole 25d formed in the axial center portion thereof in the left-right direction in FIG. 1, and a shaft 30 is inserted through the bearing 31 in the through hole 25d.
It is supported so as to be rotatable about the axis CT and slidable in the directions of arrows A and B. One end of the shaft 30 is in contact with the spool 11 of the pressure regulating valve portion, and a plunger 37 is integrally fixed to the other end portion of the shaft 30, and the plunger 37 is attached to the solenoid coil assembly 29. It can be sucked and moved in the case 39 in the axial direction which is the arrow A, B direction. Therefore, the shaft 30 is attached to the plunger 37.
It moves together with and substantially forms a part of the plunger.

Since the linear solenoid valve 6 has the above-mentioned structure, the linear solenoid valve 6 has the exciting coil 3 of the solenoid coil assembly 29 of the electromagnet section 9.
3 is appropriately excited to move the plunger 37 and the shaft 30 in the arrow A direction by an electromagnetic force according to the exciting current.
Then, the spool 11 of the pressure regulating valve portion 7 is also pushed by the shaft 30 to resist the elastic force of the coil spring 12 which is adjusted to an appropriate biasing force by the adjusting bolt 28 and is indicated by an arrow A.
And is held in a position where the electromagnetic force acting from the shaft 30 and the elastic force of the coil spring 12 are balanced. Then, the pressure oil supplied from the supply port 19 of the pressure regulating valve unit 7 is appropriately squeezed by the lands 21 and 22 of the spool 11, and the supply of the pressure oil is controlled, and the pressure oil in the controlled state is output. The remaining pressure oil is supplied from the port 17 to the controlled object, and the remaining pressure oil is drained from the drain port 16. It should be noted that part of the pressure oil in the output port 17 is returned to the feedback pressure chamber 20 and supplied so as to urge the spool 11 in the direction of arrow B in FIG.

By the way, the solenoid coil assembly 29 constituting the electromagnet portion 9 of the linear solenoid valve 6 is assembled in the following manner. That is, first, FIG.
As shown in (a), the bobbin 26 is integrally molded with the connector base 32a of the connector portion 32 by an insulating resin,
Next, as shown in FIG.
The coil winding portion 25a of the core 25 is inserted into the coil winding portion 26a of the bobbin 26, and the two positioning protrusions 26d of the bobbin 26 are attached to the flange portion 2 of the core 25.
5f of two positioning holes 25b are inserted and engaged, and at the same time, the connector base 32a is fitted and engaged with the connector mounting portion 25g of the flange portion 25f. In FIG. 5B, reference numeral 41 is a bush used in manufacturing the solenoid coil assembly 29.

In this state, as shown in FIG. 5B, the connector mounting portion 25g enters into the flange portion 25f of the core 25 and is housed in the flange portion 25f, and the coil winding portion 25e of the core 25 is inserted. Does not stick out. Next, as shown in FIG. 4, the integrally assembled core 25 and bobbin 26 are set on the winding machine 42, and the core 25 and bobbin 2 are set.
6 is integrally rotated, for example, in the direction of arrow K, and the bobbin 26
The exciting coil 33 is wound around the coil winding portion 26a of a predetermined number of turns, but the connector base 32a integrally formed with the bobbin 26 has the flange portion 2 of the core 25 as described above.
Since it does not protrude into the coil winding portion 25e of the core 25 by entering the inside of 5f, the exciting coil 33 is wound in such a manner that the length of the coil winding portion 25e of the core 25 in the horizontal direction in the drawing is effectively used. With the same number of windings, the size of the exciting coil 33 in the radial direction at the time of completion of winding can be reduced accordingly, and more windings can be obtained with the same size of winding completion size.

When the core 25 is set on the winding machine 42, the positioning holes 25b, 25b formed in the flange portion 25f of the core 25 (as described above, the tapered portion 2)
(The empty space is formed in the portion 5c), the positioning pins 42a, 42a of the winding machine 42 are fitted into and engaged with the positioning holes 25b, 25b, and the collar portion 26b of the bobbin 26 on the opposite side is pushed. The bobbin 26 is pinched and held while being pressed by 42b, and the bobbin 26 is rotated in that state. The bobbin 26 is also positioned with respect to the core 25 by the positioning protrusion 26d and the positioning hole 25b. And the bobbin 26 is the bobbin 26.
The core 25 and the core 25 smoothly rotate integrally in the direction of the arrow K without moving in the rotational direction, and a smooth winding operation can be performed.

Since the positioning hole 25b of the core 25 is formed with the tapered portion 25c, the pin 42a of the winding machine 42 can be easily engaged with the positioning hole 25b by the tapered portion 25c.

Thus, the coil winding portion 26 of the bobbin 26
When the exciting coil 33 has been wound a predetermined number of times on a, a terminal 32c is attached to the connector base 32a, and the wound exciting coil 33 is connected to the terminal 32c, as shown in FIG. 5 (c). When the exciting coil 33 is wound and in the wound state, the coil winding portion 26a of the bobbin 26 is integrated with the coil winding portion 25e of the core 25 having high rigidity due to the winding force of the exciting coil 33. Since the bobbin 26 is wound in a shape, the exciting coil 33 can be smoothly wound without causing harmful deformation to the bobbin 26 even if the rigidity of the bobbin 26 is not so high. The thickness can be made smaller than that of the conventional bobbin 5 shown in FIG. 7, which contributes to the miniaturization of the solenoid coil assembly 28.

Next, as shown in FIG. 5D, the bobbin 26 around which the exciting coil 33 is wound, the core 25, and the terminal 32.
Secondary molding is performed on the connector base 32a mounted with c by resin to mold the main body 32b and the cover 32d of the connector portion 32, the cover 35 of the exciting coil 33, and the positioning hole 25b of the core 25 and the connector mounting. The portion 25g is also filled with resin by secondary molding to complete the solenoid coil assembly 29.

At this time, the resin obtained by the secondary molding is as shown in FIG.
The taper-shaped connector mounting portion 25g shown in (a) is filled into the gap 25h formed between the connector base 32a and the tapered portion 25c of the positioning hole 25b of the core 25. Positioning protrusion 26
Since the bobbin 26 is integrated with the core 25 through the connector base 32a and the positioning protrusions 26d, the bobbin 26 is reliably integrated with the core 25 and the filled resin acts as a wedge. It is possible to prevent the bobbin 26 around which 33 is wound from falling off in the direction of arrow J in the figure due to some shock.

When the solenoid coil assembly 29 is completed in this way, as shown in FIG.
0, the plunger 37, the case 39, etc. are attached and the electromagnet part 9 is completed.

In the above-described embodiment, the tapered connector mounting portion 25g of the core 25 is formed as a smooth flat surface as shown in FIG. 2 (a). In order to improve the adhesiveness between the resin and the core 25, as shown in FIG. 3, unevenness 25i may be formed on the tapered portion.

The connector mounting portion 25 may have any shape as long as it is formed in a concave shape with respect to the side surface 25a of the flange portion 25f. That is, as long as the connector portion 32 formed on the bobbin 26 has a form in which at least a part of the connector portion 32 can be housed in the flange portion 25f of the core 25, it does not have to be a concave portion that penetrates in the vertical direction in FIG. It may be a notch or a recess formed on the coil winding portion 25e side of the flange portion 25f.

The solenoid coil assembly 29 is not limited to the linear solenoid type, but can be applied to a normal, non-linear type solenoid coil assembly.

[Brief description of drawings]

FIG. 1 is a diagram showing an example of a linear solenoid valve.

2A and 2B are diagrams showing a core of an electromagnet portion of the linear solenoid valve shown in FIG. 1, in which FIG. 2A is a plan view and FIG.
(C) is an EE sectional view of (b).

FIG. 3 is a diagram showing another example of a connector mounting portion.

FIG. 4 is a view showing how an exciting coil is wound around a core and a bobbin.

FIG. 5 is a diagram showing an example of a manufacturing process of a solenoid coil assembly.

FIG. 6 is a front view showing a conventional solenoid coil assembly.

FIG. 7 is a side view showing a conventional solenoid coil assembly.

[Explanation of symbols]

25 cores 25a side 25b Positioning hole 25c taper part 25e Cylindrical part (coil winding part) 26a Coil winding section 25f flange 25g Connector storage part (connector mounting part) 25i unevenness 26 bobbins 29 Solenoid coil assembly 32 connector 32c terminal 33 Excitation coil

─────────────────────────────────────────────────── ─── Continuation of the front page (58) Fields surveyed (Int.Cl. ⁷ , DB name) H01F 7/06

Claims (7)

(57) [Claims] 1. A bobbin comprising: a core having a tubular portion and a flange portion provided on one of the tubular portions; and a bobbin having a coil winding portion fitted in the tubular portion. In a solenoid coil assembly in which an exciting coil is wound around a coil winding portion, and a connector portion having terminals is provided on the bobbin, a concave connector accommodating portion is formed in a flange portion of the core, and A solenoid coil assembly, wherein the connector part of the bobbin is installed in the connector housing part such that at least a part of the connector part is housed in the flange part. 2. A coil winding portion of the bobbin is made thin, and the exciting coil is wound around the coil winding portion of the core while the coil winding portion of the bobbin is fitted in the tubular portion of the core. The solenoid coil assembly according to claim 1, wherein the bobbin is integrally fixed to the core by deforming the coil winding portion by installing the coil winding portion. 3. The connector accommodating portion is a groove that penetrates the flange portion in the axial direction of the core and is formed in a tapered shape that becomes narrower toward the tubular portion. Alternatively, the solenoid coil assembly according to item 2. 4. The solenoid coil assembly according to claim 3, wherein the groove is uneven. 5. A positioning hole is formed through the flange portion of the core, the bobbin is engaged with the positioning hole, and the positioning hole has at least a side surface opposite to the tubular portion and a side surface opposite the side surface. The solenoid coil assembly according to any one of claims 1 to 4, wherein a tapered portion having a large diameter is formed. 6. The solenoid coil assembly according to claim 1, wherein the solenoid coil assembly is a linear solenoid type solenoid coil assembly. 7. A core having a tubular portion and a flange portion provided on one of the tubular portions is used, and a concave connector accommodating portion and a positioning hole are formed in the flange portion of the core. The core is inserted into a bobbin provided with a tubular coil winding portion, the tubular portion of the core is inserted into the coil winding portion of the bobbin, and the bobbin is engaged with the positioning hole to form the bobbin and the core. The bobbin coil is installed so that relative rotation is prevented and at least a part of the connector section is housed in the connector housing section, and in that state, the bobbin and the core are integrally rotated to form a coil of the bobbin. A method of manufacturing a solenoid coil assembly, comprising winding an exciting coil around a winding portion, and integrating the core and the bobbin after the winding of the exciting coil by resin formation.