JP4039931B2 - Electromagnetic actuator and manufacturing method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an electromagnetic actuator used as a coil for an electromagnetic valve, a stator for an electromagnetic valve, a coil for an electric valve, a stator for an electric valve, and the like, and a method for manufacturing the same.
[0002]
[Prior art]
For example, a magnet wire is wound inside an assembly in which a substantially circular inner box having inner magnetic pole teeth and a substantially circular outer box having outer magnetic pole teeth are alternately meshed with each other. 2. Description of the Related Art Resin-sealed electromagnetic actuators in which bobbins are inserted and stacked in two stages are used as electromagnetic valve coils, electromagnetic valve stators, electric valve coils, electric valve stators, and the like.
[0003]
Conventionally, in such an electromagnetic actuator, for example, as shown in FIG. 11 disclosed in Japanese Patent Laid-Open No. 2000-262024, a resin mold 60 is set on the outside of the yoke 1, and resin is supplied from a gate 69. By injecting and filling the resin between the first box 10U and the second box 10L, the magnet wire wound around the first box 10U and the second box 10L is protected and at the same time They are integrated by a resin filled with bobbins arranged in two stages (see, for example, Patent Document 1).
[0004]
[Patent Document 1]
Japanese Patent Laid-Open No. 2000-262024 (Page 2, FIGS. 3 and 4)
[0005]
[Problems to be solved by the invention]
By the way, since the conventional electromagnetic actuator manufacturing method described above is a method of injecting resin in the radial direction from the outside of the yoke 1, for example, using three gates 69 in which resin is injected in the radial direction. There has been a problem that the mold structure for providing is complicated. Also, in this way, in the conventional manufacturing method in which the resin is injected in the radial direction from the three gates, the direction around the resin is likely to be unbalanced, the amount of resin flow is large near the gate, and at a position far from the gate, There was a problem that the molten resin was difficult to flow uniformly.
[0006]
Further, since a runner is necessary as a resin flow path in the vicinity of the gate, there is a problem that a lot of resin solidified by the runner is wasted.
Furthermore, in the conventional manufacturing method, since the resin injected from the gate 69 is directly jetted onto the magnet wire wound around the bobbin, there is a possibility that the wire will be wavy or twisted due to the momentum of the resin. . In this way, if the wire is wavy or twisted, the wire is broken, which adversely affects the generation of magnetic force.
[0007]
In view of such an actual situation, the present invention has an easy structure of a mold apparatus for molding a resin, can make the flow of the resin substantially uniform, and a small amount of resin is wasted. Electromagnetic actuator that minimizes the deformation and breakage of the magnet wire as much as possible, does not adversely affect the generation of magnetic force, and can sufficiently increase the mechanical strength of the molded product. And it aims at providing the manufacturing method.
[0008]
[Means for Solving the Problems]
In order to achieve the above object, an electromagnetic actuator according to the present invention comprises:
The first bobbin around which the wire is wound and the second bobbin around which the wire is wound are arranged so as to overlap each other, and an inner magnetic pole tooth is provided between the two bobbins arranged in two upper and lower stages. By arranging the first inner box and the second inner box having the inner magnetic pole teeth in an overlapping manner, a sealing coil body in a temporarily fixed state composed of two bobbins and two inner boxes is formed, and resin In integrating the sealing coil body with the resin injected into the mold,
Resin circulation holes are formed in the outer periphery of the first inner box and the second inner box, and the first inner box and the second inner box are overlapped with each other such that the resin circulation holes coincide with each other. By combining, when the resin is injected into the resin mold, the resin flows in through the resin flow holes of the first inner box and the second inner box, and then the injected resin is solidified. Thus, a connecting portion made of resin between the first bobbin and the second bobbin is formed in these resin circulation holes.
[0009]
According to the electromagnetic actuator having such a configuration, since the resin flow holes are formed in the first inner box and the second inner box, the temporarily-sealed sealing coil body is integrated with the resin in the resin mold. In this case, a part of the injected resin is solidified in the resin flow hole formed by combining the two resin flow holes. Therefore, since the resin straddling the first inner box and the second inner box constitutes the connecting portion, the resin-molded sealing coil body is firmly integrated.
[0010]
The electromagnetic actuator according to the present invention is
The first bobbin around which the wire is wound and the second bobbin around which the wire is wound are arranged so as to overlap each other, and an inner magnetic pole tooth is provided between the two bobbins arranged in two upper and lower stages. By arranging the first inner box and the second inner box having the inner magnetic pole teeth in an overlapping manner, a sealing coil body in a temporarily fixed state composed of two bobbins and two inner boxes is configured,
A bobbin unit is configured by assembling the first outer box having the outer magnetic pole teeth and the second outer box having the outer magnetic pole teeth on the outside of the sealing coil body,
Furthermore, when the bobbin unit is accommodated in a resin mold and the bobbin unit is integrated with the resin injected into the resin mold,
A plurality of holes are formed in at least one of the first outer box and the second outer box,
And the resin circulation hole is formed in the outer peripheral part of the said 1st inner box and the said 2nd inner box, respectively.
Furthermore, the first inner box and the second inner box are assembled in a state where these resin flow holes are matched in advance,
The resin flows from the resin mold gate and at least one hole formed in the outer box through the resin inner hole formed in the first inner box and the second inner box, and then the resin. By solidifying the resin that has flowed in the flow holes, a connecting portion between the first bobbin and the second bobbin is formed in the resin flow holes, and the first outer box and the The second outer box is characterized in that it is embedded in a surface layer formed of resin.
[0011]
Even in such an electromagnetic actuator, the mechanical strength can be improved by the connecting portion made of the resin solidified in the resin flow hole.
Furthermore, the manufacturing method of the electromagnetic actuator according to the present invention includes:
A substantially circular first inner box and inner magnetic pole teeth each having inner magnetic pole teeth on the inner end face of the first bobbin wound with the wire and the inner end face of the second bobbin wound with the wire, respectively. By arranging a substantially circular second inner box having a sealing coil body in which two inner boxes are stacked between the first bobbin and the second bobbin,
Resin circulation holes are formed in the outer peripheral portions of the first inner box and the second inner box, and the resin circulation holes of the first inner box and the second inner box are made to coincide with each other. In this state, the sealing coil body is accommodated in a resin mold,
The resin injected into this resin mold flows into the resin flow hole, and after solidification, constitutes a connecting portion made of resin,
Thereafter, a substantially circular first outer box and second outer box having outer magnetic pole teeth are attached to the outside of the molded body taken out from the resin mold.
[0012]
The manufacturing method of the electromagnetic actuator having such a structure is not only to improve the mechanical strength by the action of the connecting portion by the resin, but the outer box provided with the outer magnetic pole teeth is attached in a later step. Its manufacture is easy.
Furthermore, the manufacturing method of the electromagnetic actuator according to the present invention includes:
Wires are wound in the inner spaces of the first assembly and the second assembly, respectively, which are formed by alternately engaging the inner case having the inner magnetic pole teeth and the outer case having the outer magnetic pole teeth with the magnetic pole teeth. A first bobbin assembly and a second bobbin assembly are inserted by inserting the first bobbin and the second bobbin,
By arranging the first bobbin assembly and the second bobbin assembly so as to overlap each other, one bobbin unit is constituted,
A resin circulation hole is formed in the outer peripheral portion of each inner box, and a plurality of holes are formed in at least one of the outer boxes,
When the first bobbin assembly and the second bobbin assembly are stacked one above the other, the resin flow holes formed in the respective inner casings are matched with each other, and the bobbin unit is placed in the resin mold. The resin injected from the gate of the resin mold is flown into the resin flow hole through the hole formed in at least one of the outer casings, and the resin solidified in the resin flow hole later, The first bobbin and the second bobbin are integrated with each other, and each outer casing is embedded in the injected surface resin layer.
[0013]
According to the manufacturing method of such a configuration, the mechanical strength is improved by the action of the connecting portion by the resin, and the whole can be covered with the resin by one injection, so that the labor can be saved. Further, since the outer box is embedded in the injected resin, the mechanical strength is improved.
[0014]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
1 is a plan view of an electromagnetic actuator according to an embodiment of the present invention, FIG. 2 is a cross-sectional view thereof, and FIG. 3 is an exploded perspective view of a sealing coil body before resin molding of the electromagnetic actuator shown in FIG. is there.
[0015]
The entire electromagnetic actuator 2 of this embodiment is formed in a substantially cylindrical shape, and as shown in FIG. 2, the lead pin 6 disposed on one side thereof is covered with a resin cover 4.
As shown in the exploded perspective view of FIG. 3, the electromagnetic actuator 2 is mainly composed of a three-element assembly of the outer box 8, the inner box 12, and the bobbin 14. The basic unit is configured. Then, two sets of such basic units are prepared and stacked one on top of the other with the outer box 8 removed, and then a resin is molded on the peripheral surface of the bobbin unit around which the wire is wound, as will be described later. Yes. In the following description, for convenience, the upper basic unit side is referred to as a “first side”, the lower basic unit side is referred to as a “second side”, and the lower side includes “second” and “′”. To distinguish it from the upper side.
[0016]
That is, the first basic unit S is composed of a first outer box 8, a first inner box 12, and a first bobbin 14, and the second basic unit T is a second outer box 8 '. It consists of a second inner box 12 'and a second bobbin 14'.
In the following, the three components constituting the basic units S and T will be described. Since the first side and the second side have the same structure, only the first side will be described.
[0017]
First, the first outer box 8 and the first inner box 12 are made of metal and are paired with each other. On the inner peripheral edge of the first outer box 8, outer magnetic pole teeth 8a are formed. Inner magnetic pole teeth 12 a are formed on the inner peripheral edge of the first inner box 12. Further, a notch 8 c is formed at one end of the first outer box 8. Further, a small hole 8d is formed in the first outer box 8. Further, a small protruding piece 8 e is formed to protrude from the opening end surface of the first outer box 8. These protruding pieces 8e are formed at predetermined intervals.
[0018]
On the other hand, the inner magnetic pole teeth 12a are formed at predetermined intervals on the inner peripheral edge of the first inner box 12, and at one end of the first inner box 12, the first outer box 8 Similarly, a notch 12b is formed.
Furthermore, resin flow holes 12c are formed in the first inner box 12 at predetermined intervals along the outer peripheral surface. Further, in the embodiment, three cutout grooves 12d are formed at predetermined intervals on the outer peripheral edge of the first inner box 12. These cutout grooves 12d are formed at positions corresponding to the protruding pieces 8e of the first outer box 8 when the first outer box 8 is overlapped. When the first inner box 12 and the first outer box 8 are combined with each other, the protruding piece 8e is locked in the notch groove 12d.
[0019]
On the other hand, a magnet wire is wound around the peripheral surface of the first bobbin 14, and the inner magnetic pole teeth 12 a of the first inner box 12 and the outer magnetic pole teeth 8 a of the first outer box 8 are arranged at the center. A through-hole 14c is formed for receiving and locking. In addition, on the upper surface of the first bobbin 14, three convex portions 14a are formed at predetermined intervals. A lead pin 6 is planted on one side of the first bobbin 14. And the lead pin 6 provided in the 1st bobbin 14 and the lead pin 6 'provided in 2nd bobbin 14' are formed alternately so that it may not collide.
[0020]
The first outer box 8, the first bobbin 14, and the first inner box 12 that constitute the first basic unit S of the electromagnetic actuator 2 are configured as described above. Will be described. In addition, also in the assembly of these three members, the first basic unit S and the second basic unit T are assembled in the same manner.
[0021]
For example, first, the inner magnetic pole teeth 12 a of the first inner box 12 are fitted into the through holes 14 c of the first bobbin 14. As a result, the inner magnetic pole teeth 12 a are locked to the inner peripheral surface of the through hole 14 c of the first bobbin 14.
Next, as shown in FIG. 4, the first bobbin 14 fitted with the first inner box 12 and the second bobbin 14 'fitted with the second inner box 12' are stacked one above the other. At the same time, a pre-molded resin cover 4 is attached to the outside of the portion where the lead pins 6, 6 'are implanted. Thereby, the sealing coil body A is comprised. Here, the sealing coil A is not yet completely integrated, but is temporarily combined. Further, the periphery of the lead pins 6 and 6 ′ is protected by the resin cover 4.
[0022]
In this way, in the temporarily-sealed sealing coil body A composed of the first bobbin 14 and the second bobbin 14 ′, the first inner box 12 and the second inner box 12 ′, etc., FIG. As shown, the notches 12b of the first inner box 12 and the notches 12b 'of the second inner box 12 ′ are arranged in a straight line, so that it is identified that they are correctly stacked.
Thus, by assembling the sealing coil body A, the resin flow holes 12c and 12c ′ of the first inner box 12 and the second inner box 12 ′ are aligned with each other, and one communication is made in the vertical direction. A hole will be formed.
[0023]
Next, in this embodiment, a resin mold is set outside the sealing coil body A as shown in FIG. For example, if the resin is injected from the gate (not shown) provided on the first bobbin 14 side toward the other second bobbin 14 'as shown by the arrow a, the sealing coil is temporarily fixed. Resin flows in so as to sew the gap inside the body A, and a part of the resin flows as shown by the arrow b through the resin circulation holes 12c, 12c ′ and the like. Thereby, the outer peripheral surface of a magnet wire is protected. At this time, the injected resin is not directly injected onto the magnet wire, but after flowing in the axial direction, the flow is changed in the circumferential direction and comes into contact with the magnet wire in the flow. Therefore, the magnet wire is rarely deformed by being bent or waved by the force of the resin. Moreover, the resin injected from the gate flows through the resin flow holes 12c and 12c ′, which are one of the first inner box 12 and the second inner box 12 ′, and when a predetermined time has passed, the hole 12c. , 12c ′. Therefore, after the resin is cured here, a connecting portion made of the resin is formed in such a manner as to straddle the first inner box 12 and the second inner box 12 ′. Thereafter, when the resin mold is released, as shown in FIG. 6, the sealed coil body A in which the surface layers P and P ′ of the resin are formed on the outer peripheral portion is formed. In addition, although it cannot visually recognize from the outside inside the sealing coil body A, as described above, the connecting portion is configured by the resin solidified in the resin circulation holes 12c and 12c ′.
[0024]
On the other hand, the notched grooves 12d and 12d ′ formed on the outer peripheral edges of the first inner box 12 and the second inner box 12 ′ are exposed to the outside from the surface layers P and P ′.
In the present embodiment, thereafter, as shown in FIG. 6 or FIG. 3, the first outer box 8 and the second outer box 8 ′ formed from metal are mounted in advance. That is, the first outer box 8 and the second outer box 8 ′ made of metal are attached to the outer peripheral portion of the sealing coil body A integrally molded with resin in a separate process. Here, the outer magnetic pole teeth 8a of the first outer box 8 are inserted into the through holes 14c from above the sealing coil body A, and the outer magnetic pole teeth 8a 'of the second outer box 8' are sealed coil bodies. It is inserted into the through hole 14c from below A. Thus, the first outer box 8 and the second outer box 8 ′ are attached to the resin-molded sealing coil body A. Then, the protruding piece 8e of the first outer box 8 is matched with the notch groove 12d of the corresponding first inner box 12, and the protruding piece 8e 'of the second outer box 8' corresponds to the corresponding second portion. It fits in the notch groove 12d 'of the inner box 12'.
At this time, the outer magnetic pole teeth 8a of the first outer box 8 and the inner magnetic pole teeth 12a of the first inner box 12 are alternately engaged with each other, so that the first outer box 8 rotates in the circumferential direction. Is prevented. Similarly, the rotation of the second outer box 8 ′ in the circumferential direction is prevented.
[0025]
Thereafter, in the present embodiment, for example, spot welding is performed on the butt end surface of the first outer box 8 and the second outer box 8 ′, thereby the first outer box 8 and the second outer box. 8 'is integrally connected. Thereby, the assembly of the electromagnetic actuator 2 is completed.
In the electromagnetic actuator 2 manufactured in this way, as described above, the resin that has flowed into the resin circulation holes 12c and 12c ′ is solidified in the resin circulation holes 12c and 12c ′. It constitutes a connecting part. Therefore, it is very strong in strength. Furthermore, in this embodiment, since the injection direction of the resin is the axial direction of the bobbin 14, the injected resin is not directly jetted to the circumferential surface of the magnet wire, but flows from the axial direction to the circumferential direction. After the change, since the wire is gradually supplied to the outer peripheral surface of the wire, the thin wire is less likely to be deformed due to twisting or undulation. Therefore, there is no problem in forming a magnetic field during energization. Of course, no wire breakage occurs.
[0026]
The electromagnetic actuator according to one embodiment of the present invention and the preferred manufacturing method thereof have been described above, but the present invention is not limited to this embodiment.
For example, in the above embodiment, as shown in FIG. 5, when the sealing coil body A that is temporarily fixed and not yet completely integrated is resin-molded in the resin mold, Although the resin is injected from the other side (upper side in FIG. 5), in the present invention, the resin may be injected also from the other side (lower side in FIG. 5). If it does in this way, the mold by resin can be performed rapidly.
[0027]
Next, an electromagnetic actuator according to another embodiment of the present invention and a manufacturing method thereof will be described.
FIG. 7 shows an electromagnetic actuator 80 manufactured by a manufacturing method according to another embodiment, and FIG. 8 is an exploded perspective view of each component before the surface layer Q made of resin is formed on the outer periphery. FIG. 9 is a perspective view when the components shown in FIG. 8 are incorporated into each other.
[0028]
First, the electromagnetic actuator 80 manufactured by the manufacturing method of this embodiment differs greatly from the electromagnetic actuator 2 shown in FIG. 1 in that the electromagnetic actuator 80 shown in FIG. The second outer box 50 'made of metal as well as the first outer box 50 made of metal is embedded in the surface layer Q made of resin.
That is, in the electromagnetic actuator 80 manufactured in the present embodiment, the first basic unit S is constituted by three elements of the metal first outer box 50, the first bobbin 52, and the first inner box 54. (First bobbin assembly S) is formed, and the second basic unit is constituted by three elements of a metal second outer box 50 ', a second bobbin 52', and a second inner box 54 '. T (second bobbin assembly T) is configured. These basic units S and T have the same configuration as in the above embodiment.
[0029]
Further, as shown in FIG. 9, the first bobbin assembly S and the second bobbin assembly T are stacked one above the other to constitute a bobbin unit U before the resin is injected. ing. Thereafter, as shown in FIG. 7, the electromagnetic actuator 80 covered with the resin surface layer Q is formed by embedding the bobbin unit U, that is, by molding resin on the inner periphery and outer periphery thereof. Will be formed.
[0030]
Hereinafter, with respect to the configuration of the electromagnetic actuator 80 according to the present embodiment, differences from the above embodiment will be mainly described.
The first outer box 50 according to the present embodiment is the same as the first outer box 8 shown in FIG. 3 in that it has outer magnetic pole teeth 50a at its inner peripheral edge. The first outer box 50 is different from the first outer box 8 in the above-described embodiment in that the first outer box 8 has a main opening other than the small hole 8d. On the other hand, in the first outer box 50, in addition to two small holes 50b corresponding to the small holes 8d, a large number of rectangular holes 50c are formed. That is, in this embodiment, as will be described later, the resin injected from the gate is injected into the numerous holes 50c.
[0031]
Further, a pair of protrusions 52a and 52a of the first bobbin 52 described later are matched with the two small holes 50b and 50b.
The first bobbin 52 is formed in substantially the same manner as the first bobbin 14 of the above-described embodiment, and the lead pin 6 is implanted at one end and a through hole 52c is formed at the center. Further, a pair of protrusions 52a and 52a (52a ′ and 52a ′) are formed on the upper surface side of the first bobbin 52 and on the lower surface side of the second bobbin 52 ′.
[0032]
The first inner box 54 is formed with inner magnetic pole teeth 54 a at the inner peripheral edge. Further, a linear notch 54 b is formed at one end of the first inner box 54. On the other hand, a relatively large cutout groove 54c is formed at the other end of the first inner box 54, and the cutout groove 54c corresponds to the resin flow hole 12c in the above embodiment.
Each of the three members 50, 52, and 54 in the present embodiment is configured as described above, and the assembly will be described below.
[0033]
When these are assembled, first, the first inner box 54 is fitted on the lower surface of the first bobbin 52. As a result, the inner magnetic pole teeth 54 a of the first inner box 54 are locked to the inner peripheral surface of the through hole 52 c of the first bobbin 52. Similarly, the second bobbin 52 ′ and the second inner box 54 ′ are fitted together. Then, the sealing coil body in a temporarily fixed state is configured by superimposing these in two upper and lower stages.
[0034]
Further, as shown in FIG. 9, the bobbin unit U is configured by matching the first outer box 50 from above and the second outer box 50 ′ from below. As shown in FIG. 9, a bobbin unit U in which a first bobbin assembly S (first basic unit S) and a second bobbin assembly T (second basic unit T) are vertically stacked. Are formed with gaps for the resin to flow into the upper and lower surfaces, and further to the side of the periphery.
[0035]
Then, resin is injected into the inside and outside of the bobbin unit U as described below.
That is, first, as shown in FIG. 10, the resin mold Z is set outside the bobbin unit U. Then, the resin is injected from the gate 70 of the resin mold Z, and the resin is injected inward from the numerous holes 50c of the bobbin unit U. The resin injected from the numerous holes 50c flows as shown by the arrow e, and covers the entire gap.
[0036]
Thus, after the resin is injected from the gate 70 and the hole 50c, if the resin mold Z is released after a predetermined time has elapsed, the resin is injected into the inner peripheral portion and the outer peripheral portion of the bobbin unit U as shown in FIG. Thus, the electromagnetic actuator 80, which is entirely covered with resin, is manufactured.
In the present embodiment, the cutout grooves 54c and 54c ′ and the cutouts 54b and 54b ′ of the first inner box 54 and the second inner box 54 ′ function as resin flow holes. And the resin led out downward through these resin circulation holes is led out of the second outer box 50 'through the numerous holes 50c' of the second outer box 50 '. become. A part of the resin is guided downward through the outside of the first outer box 50. Then, the resin introduced around the second outer box 50 'covers the outer surface of the first outer box 50 or the second outer box 50'. As a result, as shown in FIG. 7, the electromagnetic actuator 80 in which the first outer box 50 and the second outer box 50 ′ are embedded in the surface layer Q of resin is formed.
The first inner box 54 and the second inner box 54 ′ may be provided with resin flow holes corresponding to the resin flow holes 12c and 12c ′ of the above embodiment, instead of the notch grooves 54c and 54c ′. .
[0037]
In the electromagnetic actuator 80 according to the present embodiment, since the first outer box 50 and the second outer box 50 ′ are embedded in the surface layer Q, it is not necessary to perform spot welding, and only the resin is injected. Thus, the outer boxes 50 and 50 'do not move.
Furthermore, in this embodiment, since a runner for injecting the resin is not particularly required for the resin mold, less resin is wasted.
[0038]
As mentioned above, although the Example of this invention was described, this invention is not limited to the said Example at all.
For example, in the above embodiment, the gate 70 is provided on the first outer box 50 side, and the resin is injected from the gate 70. However, the present invention is not limited to this, and the gate 70 is also provided on the second outer box 50 'side. 'May be provided to inject the resin from both sides.
[0039]
【The invention's effect】
As described above, according to the electromagnetic actuator according to the present invention, if the resin flow holes formed in the first inner box and the second inner box are matched with each other and the resin is injected into the inner holes, The resin is solidified inside. Therefore, if the resin inside hardens after a predetermined time has elapsed, the resin straddling both sides of the first inner box and the second inner box constitutes the connecting portion, and the mechanical strength becomes strong.
[0040]
In addition, in the case where the first and second outer boxes are attached in separate steps, it is not necessary to prepare a complicated resin mold, so that workability is improved.
Furthermore, even when the first and second outer boxes are embedded in the resin integrally, the resin can be molded inside and outside the bobbin unit by one injection, so that workability is improved. In addition, since a metal outer box is embedded, sufficient mechanical strength can be obtained.
[0041]
In addition, according to the manufacturing method of the present invention, since a useless resin is not formed as a runner portion as in the prior art, the amount of resin to be used can be reduced, contributing to cost reduction and easy mold structure. Can be.
[Brief description of the drawings]
FIG. 1 is a plan view of an electromagnetic actuator according to an embodiment of the present invention.
FIG. 2 is a cross-sectional view of the electromagnetic actuator shown in FIG.
FIG. 3 is an exploded perspective view before injecting resin onto the members constituting the electromagnetic actuator shown in FIG. 1;
4 is a perspective view of a sealing coil body that is constructed when the components shown in FIG. 3 are incorporated and a resin cover is attached to a lead pin. FIG.
5 is a schematic view when a resin mold is incorporated in the sealing coil body shown in FIG. 4 and a resin is injected. FIG.
6 is a perspective view in the case where first and second outer boxes are attached to the outside after injecting resin into the sealed coil body shown in FIG. 5; FIG.
FIG. 7 is a perspective view of an electromagnetic actuator manufactured by a manufacturing method according to another embodiment of the present invention.
FIG. 8 is an exploded perspective view of the first basic unit and the second basic unit that are overlaid before the electromagnetic actuator shown in FIG. 7 is filled with resin.
FIG. 9 is a perspective view of a bobbin unit configured when the first basic unit and the second basic unit shown in FIG. 8 are incorporated.
10 is a perspective view schematically showing a state when a resin mold is set on the bobbin unit shown in FIG. 9. FIG.
FIG. 11 is a cross-sectional view showing a conventional method of manufacturing an electromagnetic actuator.
[Explanation of symbols]
2 Electromagnetic actuator 4 Cover 6 made of resin Lead pin 8a First outer magnetic pole tooth 8a 'Second outer magnetic pole tooth 8 First outer box 8' Second outer box 12a, 12a 'Inner magnetic pole tooth 12 First inner Box 12 'Second inner box 12c, 12c' Resin flow hole 14 First bobbin 14 'Second bobbin 50a, 50a' Outer magnetic pole teeth 50 First outer box 50 'Second outer box 52 First Bobbin 52 ′ Second bobbin 54a First inner magnetic pole tooth 54a ′ Second inner magnetic pole tooth 54 First inner box 54 ′ Second inner box 70 Gate 80 Electromagnetic actuator A Sealing coil bodies P, Q Surface layer S First basic unit (first bobbin assembly)
T Second basic unit (second bobbin assembly)
U Bobbin unit Z Resin mold

Claims (4)

The first bobbin around which the wire is wound and the second bobbin around which the wire is wound are arranged so as to overlap each other, and an inner magnetic pole tooth is provided between the two bobbins arranged in two upper and lower stages. By arranging the first inner box and the second inner box having the inner magnetic pole teeth in an overlapping manner, a sealing coil body in a temporarily fixed state composed of two bobbins and two inner boxes is formed, and resin In integrating the sealing coil body with the resin injected into the mold,
Resin circulation holes are formed in the outer periphery of the first inner box and the second inner box, and the first inner box and the second inner box are overlapped with each other such that the resin circulation holes coincide with each other. By combining, when the resin is injected into the resin mold, the resin flows in through the resin flow holes of the first inner box and the second inner box, and then the injected resin is solidified. Accordingly, an electromagnetic actuator in which a connecting portion made of resin between the first bobbin and the second bobbin is formed in these resin flow holes. The first bobbin around which the wire is wound and the second bobbin around which the wire is wound are arranged so as to overlap each other, and an inner magnetic pole tooth is provided between the two bobbins arranged in two upper and lower stages. By arranging the first inner box and the second inner box having the inner magnetic pole teeth in an overlapping manner, a sealing coil body in a temporarily fixed state composed of two bobbins and two inner boxes is configured,
A bobbin unit is configured by assembling the first outer box having the outer magnetic pole teeth and the second outer box having the outer magnetic pole teeth on the outside of the sealing coil body,
Furthermore, when the bobbin unit is accommodated in a resin mold and the bobbin unit is integrated with the resin injected into the resin mold,
A plurality of holes are formed in at least one of the first outer box and the second outer box,
And the resin circulation hole is formed in the outer peripheral part of the said 1st inner box and the said 2nd inner box, respectively.
Furthermore, the first inner box and the second inner box are assembled in a state where these resin flow holes are matched in advance,
The resin flows from the resin mold gate and at least one hole formed in the outer box through the resin inner hole formed in the first inner box and the second inner box, and then the resin. By solidifying the resin that has flowed in the flow holes, a connecting portion between the first bobbin and the second bobbin is formed in the resin flow holes, and the first outer box and the The second outer box is an electromagnetic actuator embedded in a surface layer formed of resin. A substantially circular first inner box and inner magnetic pole teeth each having inner magnetic pole teeth on the inner end face of the first bobbin wound with the wire and the inner end face of the second bobbin wound with the wire, respectively. By arranging a substantially circular second inner box having a sealing coil body in which two inner boxes are stacked between the first bobbin and the second bobbin,
Resin circulation holes are formed in the outer peripheral portions of the first inner box and the second inner box, and the resin circulation holes of the first inner box and the second inner box are made to coincide with each other. In this state, the sealing coil body is accommodated in a resin mold,
The resin injected into this resin mold flows into the resin flow hole, and after solidification, constitutes a connecting portion made of resin,
Thereafter, a substantially circular first outer box having outer magnetic pole teeth and a second outer box are attached to the outside of the molded body taken out from the resin mold. . Wires are wound in the inner spaces of the first assembly and the second assembly, respectively, which are formed by alternately engaging the inner case having the inner magnetic pole teeth and the outer case having the outer magnetic pole teeth with the magnetic pole teeth. A first bobbin assembly and a second bobbin assembly are inserted by inserting the first bobbin and the second bobbin,
By arranging the first bobbin assembly and the second bobbin assembly so as to overlap each other, one bobbin unit is constituted,
A resin circulation hole is formed in the outer peripheral portion of each inner box, and a plurality of holes are formed in at least one of the outer boxes,
When the first bobbin assembly and the second bobbin assembly are stacked one above the other, the resin flow holes formed in the respective inner casings are matched with each other, and the bobbin unit is placed in the resin mold. The resin injected from the gate of the resin mold is flown into the resin flow hole through the hole formed in at least one of the outer casings, and the resin solidified in the resin flow hole later, A method for manufacturing an electromagnetic actuator, wherein the first bobbin and the second bobbin are integrated, and each outer casing is embedded in an injected surface resin layer.

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