JP3502439B2 - Method of manufacturing resin-molded electromagnetic device - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin-molded electromagnetic device such as a resin-molded current transformer or a resin-molded reactor, and in particular, a synthetic resin insulation layer is formed on the outer peripheral portion of a coil portion by using a mold. The present invention relates to a method of manufacturing a resin-molded electromagnetic device configured to be formed.

[0002]

2. Description of the Related Art FIG. 13 shows, for example, Japanese Patent Publication No. 59-1773.
It is a front view of the coil part which comprises the conventional resin mold type current transformer shown by the 42nd publication. FIG. 14 is a plan view of FIG. 13, and FIG. 15 is a sectional view showing a state at the time of molding. In the figure, 1 is a winding core made of an insulating material, 2 is a low voltage coil wound around the winding core 1, 3 is a main insulator wound around the outer circumference of the low voltage coil 2, for example, a polyester film is wound. It was done. Reference numeral 4 is a high-voltage coil wound around the outer periphery of the main insulator 3. Reference numeral 5a denotes a winding start lead wire of the high voltage coil 4 and 5b denotes a winding end lead wire of the high voltage coil 4. Usually, the lead wires 5a and 5b are formed by directly drawing out the end portion of the high voltage coil 4, and the low voltage coil 2 and the high voltage coil 4 and the like form a coil portion 10. 6a is a winding start terminal metal fitting connected to the winding start lead wire 5a, and 6b is a winding end terminal metal fitting connected to the winding end lead wire 5b. Coil part 1 configured in this way
When a synthetic resin molding layer is formed on the outer periphery of 0, the spacer 9 attached to the side surface of the low voltage coil 2 as shown in FIG.
Then, the coil portion is held at a predetermined position in the molding die 20 by the terminal fittings 6a and 6b at both ends, and the synthetic resin is injected to form the synthetic resin molding layer 8.

In this case, in order to hold the coil portion 10, the spacer 9 attached to the side surface of the low-voltage coil 2 is brought into contact with the inner side surface of the molding die 20 and the winding start terminal metal fitting 6a and the winding end terminal metal fitting are provided. 6b mold 20 for molding
It is performed by sandwiching the divided surface 20a. By injecting the synthetic resin in this state, the molded coil portion 11 having the synthetic resin molding layer 8 having an appropriate thickness is formed on the outer periphery of the coil portion 10.

[0004]

In the conventional resin mold type electromagnetic device as described above, the spacer 9 is usually attached to the side surface of the low voltage coil 2, but the spacer 9 is used for the spacer 9 when the number of turns of the low voltage coil 2 is small. The adhesive area is small and the spacer 9 may be obliquely adhered. Further, when the adhesive area for the spacer 9 is small, the adhesive strength is weak, and therefore the position of the spacer 9 may move during the drying process of the coil portion 10. Therefore, the thickness of the synthetic resin molding layer 8 on the side surface of the coil portion 10 may be uneven. Due to the above circumstances, the spacer 9 may not be used. In this case, the coil portion is held by sandwiching the winding start terminal metal fitting 6a and the winding end terminal metal fitting 6b by the dividing surface of the molding die 20, but the lead wire sizes of the lead wires 5a and 5b at the winding start and the winding end are If it is small, the holding state of the coil portion 10 may be eccentric due to the weight of the coil portion 10, and the thickness of the synthetic resin molding layer 8 may become inappropriate. Therefore, when the coil portion 10 is incorporated into the molding die 20, positioning work of the winding start terminal metal fitting 6a and the winding end terminal metal fitting 6b is required, resulting in poor productivity.

The present invention has been made to solve the above-mentioned problems, and when the coil portion with terminal fittings is incorporated in the molding die, the coil portion can be placed in the correct position without using a spacer. held, the thickness of the synthetic resin molded layer is more to ensure that appropriate molded coil portion is obtained,
An object of the present invention is to provide a method for manufacturing a resin-molded electromagnetic device that is excellent in workability in assembly during molding, insulation reliability, and the like.

[0006]

Means for Solving the Problems A method of manufacturing a resin mold type solenoid apparatus according to the present invention, Re et provided at one end of the coil portion wound coils of winding-start connected winding start terminal to the lead wire A metal fitting, a winding end terminal metal fitting provided at the other end of the coil portion and connected to a winding end lead wire of the coil portion, and a fixing member provided between the coil portion and each terminal metal fitting for fixing the terminal metal fitting to the coil portion, The fixing member is fixed to the coil part at one end.
Hold the fixed piece on the coil by winding the coil.
Hold it, and fix the terminal metal fitting fixing piece at the other end to the terminal metal fitting.
Then, the winding start terminal fitting and the winding end terminal fitting are respectively supported by the molding die so that the coil portion does not become eccentric within the molding die due to its own weight. Is to be molded.

Further, it is provided at one end of the wound coil portion.
Winding start terminal wire connected to the winding start lead wire of the coil
Tool, coil end winding lead provided on the other end of the coil
Winding end terminal fittings connected to the wire, coil part and each terminal fitting
A fixing member that is provided between the terminals to fix the terminal fitting to the coil
The fixing member is equipped with a coil fixing piece at one end.
Adhesive on the surface of the cable
Securely attach to the child metal fittings, and
Each coil is supported by a mold for molding,
Not to eccentrically in the mold mold by its own weight
It is made by molding a synthetic resin molding layer.
It

Further, the fixing member includes a terminal metal fitting fixing piece and a coil.
It is L-shaped or T-shaped having a fixed part.

The fixing member for holding the position of the terminal fitting is made of the same synthetic resin material as the synthetic resin material for forming the synthetic resin molding layer or an insulating material such as a ceramic material .

Further, the other end of the fixing member for holding the position of the terminal fitting and the terminal fitting are fixed to each other by providing a long hole in either the fixing member or the terminal fitting and providing a screw hole in the other and screwing them together. I wore it.

Furthermore, it provided on the pair of end portions of the coil portion wound, of the coil unit winding start lead and Makiowari lead a pair of which is formed by fixing the coil portion that ends folded respectively Equipped with overhanging parts, winding start terminal fittings and winding end terminal fittings fixed to these overhanging parts, respectively, the winding start terminal fittings and winding end terminal fittings are respectively supported by the mold for molding, and the coil part is supported by its own weight. The synthetic resin molding layer is molded so as not to be eccentric in the mold for molding.

[0012]

In the method of manufacturing the resin-molded electromagnetic device constructed as described above , the fixing member for fixing the position of the terminal fitting to the coil portion is provided between the coil portion and each of the terminal fittings. The fixing member is fixed to the coil part at one end
Put one piece on the coil by winding the coil.
Hold the other end of the terminal metal fitting fixing piece
By fixing the winding start terminal fitting and the winding end terminal fitting to the respective predetermined positions of the molding die, the coil part is eccentric in the molding die due to its own weight.
Since the molding is carried out so as not to exist, the erected fixing member works to hold the coil portion at an accurate position in the molding die.

Further , an end is provided between the coil portion and each of the above terminal fittings.
Install a fixing member to fix the position of the child metal fitting to the coil.
The coil member fixing piece at one end of the fixing member.
Glue to the surface of the coil and attach the terminal metal fixing piece on the other end.
Stick to the terminal metal fittings, winding start terminal metal fittings and winding end terminal metal fittings
Each of them into the prescribed position of the mold for molding.
Due to the coil's own weight due to
Since it is molded so as not to be eccentric inside,
The fixed member makes the coil part accurate in the mold for molding.
It works to hold it in a proper position.

Further, the fixing member is a terminal metal fixing piece and a coil.
L-shaped or T-shaped with a fixed part
It can be fixed to child metal fittings and coils.

Further, the fixing member for holding the position of the terminal fitting is made of the same synthetic resin material or ceramic material as the synthetic resin material for forming the synthetic resin molding layer. No need for insulation treatment between and.

Further, the other end of the fixing member for holding the position of the terminal fitting and the terminal fitting are fixed to each other by making a long hole in one of the fixing member and the terminal fitting and providing a screw hole in the other and screwing. By doing so, the terminal fitting can be fixed at an accurate position.

Furthermore, winding-start the overhang portion formed by fixing both ends thereof to the coil portion is provided by bending the lead wire and the winding end lead wire, respectively, each winding start terminal fitting and winding end terminal fittings on these fixed place , The winding start terminal metal fitting and the winding end terminal metal fitting are respectively fitted in predetermined positions of the mold for molding so that the coil portion is molded so as not to be eccentric in the mold for its own weight , The overhanging portion of the lead wire serves to hold the coil portion in a correct position.

[0018]

EXAMPLES Example 1. 1 to 3 show an embodiment of the present invention.
FIG. 4 is a cross-sectional view showing a state of a resin-molded current transformer at the time of molding. 2 is a front view of a state in which a fixing member is installed between the coil portion and the terminal fitting, and FIG. 3 is a perspective view of the fixing member.

In the figure, 7 is an L-shaped fixing member, which is formed by bending a rectangular copper wire into an L-shape to form a terminal metal fitting fixing piece 7a at one end and a coil portion fixing piece 7b at the other end.
An insulating tube 7c is fitted in b. Note that L
The shape fixing member 7 is formed by using a rectangular copper wire having a size having sufficient mechanical strength to hold the coil portion 10. Reference numeral 8 is, for example, a synthetic resin molding layer formed by injecting an epoxy resin, and 20 is a mold for forming the synthetic resin molding layer 8. In the above, L
The shape fixing member 7 is installed between the winding start terminal metal fitting 6a and the high voltage coil 4 or the coil portion 10, and between the winding end terminal metal fitting 6b and the high voltage coil 4 or the coil portion 10. This L-shaped fixing member 7 is installed by placing the coil fixing piece 7b fitted with the insulating tube 7c one layer before the final layer of the high voltage coil 4 and winding the final layer of the high voltage coil 4 several times. The fixing piece 7b is fixed. The terminal fitting fixing piece 7a is fixed to the winding start terminal fitting 6a by soldering. An L-shaped fixing member 7 is similarly installed between the end-of-winding terminal metal fitting 6b and the high-voltage coil 4. Note that the other configurations are the same as those of the conventional configuration shown in FIGS.

When the synthetic resin molding layer 8 is formed on the outer periphery of the coil portion 10 thus constructed, the coil portion 10 is dried and then fitted and held in the molding die 20. That is, as shown in FIG. 1, the winding start terminal metal fitting 6a and the winding end terminal metal fitting 6b are respectively provided in the mold 20 for molding.
The coil portion 10 is held by being sandwiched by the divided surfaces 20a. By injecting the synthetic resin in this state, the molded coil portion 11 having the synthetic resin molding layer 8 having an appropriate thickness is formed on the outer periphery of the coil portion 10. In the resin-molded electromagnetic device configured by using the mold coil portion 11, the L-shaped fixing member 7 is easily processed, and the winding start terminal metal fitting 6a and the winding end terminal metal fitting 6b are firmly fixed to the high voltage coil 4. Therefore, there is no problem that the holding state of the coil portion 10 in the molding die 20 is decentered due to its own weight.

Example 2. Although the L-shaped fixing member 7 having the terminal metal fitting fixing piece 7a and the coil portion fixing piece 7b is used in the first embodiment, the T-shaped flat copper wire is formed into a T shape as shown in FIG. The shape fixing member 17 can also be used. That is, the T-shaped fixing member 17 is formed into a T-shape by cutting and bending a rectangular copper wire having a width wider than that of the rectangular copper wire of Example 1, one end of which is used as a terminal metal fitting fixing piece 17a and the other end of which is fixed to a coil portion. A piece 17b is used, and an insulating tape 17c is wound around the coil part fixing piece 17b. The coil portion fixing piece 17b is formed in an arc shape along the outer circumference of the high voltage coil 4 in the winding direction.
The T-shaped fixing member 17 is installed between the winding start terminal metal fitting 6a and the high-voltage coil 4 or the coil portion 10 and between the winding end terminal metal fitting 6b and the high-voltage coil 4 or the coil portion 10.

The T-shaped fixing member 17 is installed by arranging the coil portion fixing piece 17b around which the insulating tape 17c is wound one layer before the final layer of the high voltage coil 4.
Is wound two to three times to fix the coil portion fixing piece 17b.
The terminal metal fitting fixing piece 17a is fixed to the winding start terminal metal fitting 6a by soldering. A T-shaped fixing member 17 is similarly installed between the end-of-winding terminal metal fitting 6b and the high-voltage coil 4. The synthetic resin molding layer 8 is formed in the same manner as in Example 1. In the T-shaped fixing member 17 of this embodiment, the coil portion fixing piece 17b is arranged along the outer circumference of the high voltage coil 4 in the winding direction.
Since it is formed in a relatively long arcuate shape, it can be fixed by winding the high-voltage coil 4 two to three times. That is, the T-shaped fixing member 17 can be fixed even when the final layer has a small number of turns.

Example 3. Each of the L-shaped fixing member 7 and the T-shaped fixing member 17 in the above Examples 1 and 2 is formed by using a rectangular copper wire, but the fixing member is formed by using an insulating material such as a synthetic resin material or a ceramic material. May be formed. That is, FIG.
Reference numeral 27 denotes an insulating fixing member 27, which is made of the same synthetic resin material as the synthetic resin molding layer 8 and has a terminal metal fitting fixing piece 27a and a coil portion fixing piece 27b. As for the installation of the insulating fixing member 27, the coil portion fixing piece 27b is fixed to the coil portion 10 by winding the high voltage coil 4 as in the first and second embodiments. Terminal fitting fixing piece 27
The a is fixed to the winding start terminal metal fitting 6a or the winding end terminal metal fitting 6b by adhesion. Then, the synthetic resin molding layer 8 is formed in the same manner as in the first and second embodiments. The insulation fixing member 27 of this embodiment does not need to perform insulation treatment on the coil portion fixing piece 27b, so that the insulation failure of the final layer of the high voltage coil 4 is prevented. An insulating fixing member 27 having high mechanical strength can be obtained by using a ceramic material.

Example 4. The insulating fixing member 27 in the third embodiment is provided between the winding start terminal metal fitting 6a and the high voltage coil 4 or the coil portion 10, and between the winding end terminal metal fitting 6b and the high voltage coil 4 or the coil portion 1.
It is built between 0 and. In this case, the coil fixing piece 27
The high voltage coil 4 is fixed by winding it around a, but it may be fixed with an adhesive as shown in FIG. That is, the coil fixing piece 27b is connected to the high voltage coil 4
Then, the terminal metal fitting fixing piece 27a is wound and bonded to the terminal metal fitting 6a. Similarly, the terminal metal fitting 6b at the end of winding is also bonded. Then, the synthetic resin molding layer 8 is formed in the same manner as in the first and second embodiments. In the installation of the insulation fixing member 27 in this embodiment, the positioning of the insulation fixing member 27 is easy. Note that the L-shaped fixing member 7 of the first embodiment or the T-shaped fixing member 27 of the first embodiment can also be installed by adhesion.

Example 5. Terminal fitting fixing piece 7 of the fixing member in the above-mentioned Examples 1 to 4
The a, 17a, 27a and the winding start terminal metal fitting 6a or the winding end terminal metal fitting 6b are fixed by soldering or adhesion, but as shown in FIG. 7, they may be fixed (screwed) by using machine screws. Good. For example, when the L-shaped fixing member 7 of the first embodiment is screwed, the L-shaped fixing member 37 with a slit hole shown in FIG. 8 is used. The L-shaped fixing member 37 with a slit hole has a terminal metal fixing piece 37a at one end and a slit hole 37d. The other end is a coil portion fixing piece 37
b, and the insulating tube 37c is attached to the coil fixing piece 37b.
Is fitted. This L-shaped fixing member 37 is installed
The coil portion fixing piece 37b fitted with the insulating tube 37c is arranged one layer before the final layer of the high voltage coil 4, and the high voltage coil 4 of the final layer is wound several times to fix the coil portion fixing piece 37b. As shown in FIG. 7, the terminal metal fitting fixing piece 37a is provided with screw holes in the winding start terminal metal fitting 6a and the winding end terminal metal fitting 6a, and is screwed with a washer 37e and a machine screw 37f. The synthetic resin molding layer 8 is formed in the same manner as in the first and second embodiments. The L-shaped fixing member 37 with a slit hole in this embodiment
Installation of the winding start terminal metal fitting 6a and winding end terminal metal fitting 6a
The position of can be set easily and accurately.

Example 6. In the fifth embodiment, the L-shaped fixing member 3 with the slit hole is provided.
Although 7 is screwed with a general small screw, it may be screwed with a tapping screw. When using a tapping screw for screwing, it may be configured as shown in FIG. That is, slit holes are provided in the winding start terminal metal fitting 6a and the winding end terminal metal fitting 6a, and the L-shaped fixing member 47 with a lower hole shown in FIG. 10 is used. The L-shaped fixing member 47 with a pilot hole is used for the terminal metal fitting fixing piece 4
7a is provided with a tapped screw pilot hole 47d.
This L-shaped fixing member 47 with a pilot hole is installed by using the
It is screwed using the tapping screw 47f. The formation of the synthetic resin molding layer 8 and the like are performed in the same manner as in Examples 1 to 5 above.

Example 7. In each of Examples 1 to 6 described above, the lead wire of the high voltage coil 4 is connected to the winding start terminal metal fitting 6a and the winding end terminal metal fitting 6b , and the fixing member is installed and fixed. And if configured as shown in FIG.
Can be firmly fixed only with lead wires. In the figure, 5c is an overhanging portion, and the winding start lead wire 5a of the high-voltage coil 4 is bent in a triangular shape, its tip is insulated by an insulating tube 5d, and both ends of the triangular shape are connected to the high-voltage coil 4 by insulating tapes 5e. It is tied and fixed. The winding start terminal metal fitting 6a is fixed to the overhanging portion 5c by soldering. Similarly, the winding end lead wire 5b is also bent in a triangular shape to provide an overhanging portion 5f, and the winding end terminal metal fitting 6b is fixed thereto. The synthetic resin molding layer 8 is formed in the same manner as in the first to sixth embodiments. According to this embodiment, since the fixing member is not used, the number of parts is small and the cost can be reduced.

[0028]

Since the present invention is configured as described above, it has the following effects. The present invention is not limited to the resin mold type current transformer, but can be applied to a method of manufacturing a resin mold type electromagnetic device such as a resin mold type reactor.

The erected fixing member works to hold the coil portion at an accurate position, so that a preset synthetic resin molding layer can be appropriately obtained. Further, since no spacer is used, peeling and cracking of the synthetic resin molding layer due to the spacer can be prevented. Therefore, it is possible to provide a method of manufacturing a resin-molded electromagnetic device with stable quality.

Further, since the one using the fixing member formed in the T-shape or the L-shape can be fixed even if the number of turns of the high voltage coil is small, it is easy to deal with the case of the high-voltage coil having a small number of turns in the final layer.

Further, synthetic resin material or ceramic material
In the case where the fixing member is formed of the above insulating material, it is not necessary to perform the insulating treatment on the fixing member, and therefore the insulation failure of the final layer of the high voltage coil 4 is prevented.

Further, in the case where the fixing member is fixedly adhered using an adhesive, the positioning of the fixing member 27 is easy.

Further, when the terminal metal fitting side of the fixing member and the winding start terminal metal fitting 6a or the winding end terminal metal fitting 6b are screwed through the slit holes, the position of the terminal metal fitting 6a can be set easily and accurately. .

Further, the winding start lead wire and the winding end lead wire are respectively bent and both ends of the winding wire are fixed to the coil portion, and the protruding portions are formed to fix the winding start terminal fitting and the winding end terminal fitting. Since no member is used, the number of parts is small and the cost can be reduced.

[Brief description of drawings]

FIG. 1 is a sectional view of a molded state according to a first embodiment of the present invention.

FIG. 2 is a front view of a coil unit with a terminal fitting according to the first embodiment.

FIG. 3 is a perspective view of an L-shaped fixing member according to the first embodiment.

FIG. 4 is a perspective view of a T-shaped fixing member according to Embodiment 2 of the present invention.

FIG. 5 is a perspective view of an insulation fixing member of Embodiment 3 of the present invention.

FIG. 6 is a plan view of a coil unit with a terminal fitting according to a fourth embodiment of the present invention.

FIG. 7 is a plan view of a coil part with a terminal fitting according to a fifth embodiment of the present invention.

FIG. 8 is a perspective view of an L-shaped fixing member with a slit hole according to a fifth embodiment.

FIG. 9 is a plan view of a coil part with a terminal fitting according to a sixth embodiment of the present invention.

FIG. 10 is a perspective view of an L-shaped fixing member with a pilot hole according to a sixth embodiment.

FIG. 11 is a front view of a coil part with a terminal fitting according to a seventh embodiment of the present invention.

FIG. 12 is a plan view of a coil part with a terminal fitting according to a seventh embodiment of the present invention.

FIG. 13 is a front view of a conventional coil unit with a terminal fitting.

FIG. 14 is a plan view of a conventional coil unit with a terminal fitting.

FIG. 15 is a cross-sectional view of a conventional product in a molded state.

[Explanation of symbols]

1 core, 2 low voltage coil, 3 main insulator, 4 high voltage coil, 5a winding start lead wire, 5b winding end lead wire,
6a winding start terminal metal fittings, 6b winding end terminal metal fittings, 8 synthetic resin molding layer, 10 coil portion, 20 molding die,
7, 17, 27, 37, 47 Fixed member.

─────────────────────────────────────────────────── ─── Continuation of the front page (56) Reference JP-A-5-159942 (JP, A) JP-A-5-36556 (JP, A) Actually opened 61-92039 (JP, U) Actually opened 64- 35728 (JP, U) S. 15-1858 (JP, Y1) (58) Fields investigated (Int.Cl. ⁷ , DB name) H01F 27/28 H01F 27/31 H01F 41/12

Claims (6)

(57) [Claims] 1. A wound Re et provided at one end of the coil portion upper <br/> Symbol coil portion of the winding start connected winding start terminal fitting to the lead wire, the coil provided on the other end of the coil portion A winding end terminal fitting connected to the winding end lead wire of the section, a fixing member provided between the coil section and each of the terminal fittings for fixing the terminal fitting to the coil section, and the fixing member includes :
Of the coil by fixing the coil part fixing piece at one end of
Hold it on the coil by tightening it, and fix the terminal metal fitting on the other end.
A fixed piece is fixed to the terminal metal fitting, and the winding start terminal metal fitting and the winding end terminal metal fitting are respectively supported by the mold for molding, and the coil portion is described above by its own weight in the mold for molding. A method of manufacturing a resin-molded electromagnetic device, wherein a synthetic resin molding layer is molded so as not to be eccentric . 2. A coil provided on one end of a wound coil portion
Winding start terminal metal connected to the winding start lead wire of the coil
And a winding end of the coil portion provided on the other end of the coil portion.
End terminal fitting connected to the lead wire, above coil
Between the above-mentioned terminal fittings and the terminal fittings
A fixing member for fixing the coil portion to the coil portion.
Adhesive on the surface of the cable
Secure the terminal fittings to the terminal fittings, and mold the winding start terminal fittings and winding end terminal fittings individually.
The coil part is supported by its own weight and
Synthetic resin without eccentricity in the mold for molding
Resin mold type that molds the oil molding layer
Manufacturing method of electromagnetic equipment. 3. The fixing member includes a terminal metal fitting fixing piece and a coil.
L-shaped or T-shaped having a locking part
The method for manufacturing a resin-molded electromagnetic device according to claim 2. 4. The fixing member is the same synthetic resin material as the synthetic resin material for forming the synthetic resin molding layer, or
The method for manufacturing a resin-molded electromagnetic device according to claim 1 or 2 , wherein the resin-molded electromagnetic device is formed of a ceramic insulating material. 5. The fixing member and the terminal fitting are screwed to each other by providing a long hole in one of the fixing member and the terminal fitting and a screw hole in the other. Alternatively, the method for manufacturing the resin-molded electromagnetic device according to claim 2. 6. A pair of overhangs which are provided at a pair of ends of a wound coil portion, and are formed by bending a winding start lead wire and a winding end lead wire of the coil portion and fixing both ends to the coil portion. Section, and winding start terminal fittings and winding end terminal fittings that are respectively fixed to these overhanging parts.The winding start terminal fitting and the winding end terminal fitting are supported by a mold for molding, respectively, and the coil portion has its own weight. The method for producing a resin-molded electromagnetic device, wherein a synthetic resin molding layer is molded so as not to be eccentric in the mold for molding.