JPH0232508A - Resin molded coil - Google Patents

Abstract

PURPOSE:To improve heat resistance and crack resistance by forming at least one of an inner peripheral insulating layer, an outer peripheral insulating layer, an edge part insulating layer and a space inside a winding of a resin layer, wherein a thermohardening resin composition to be specified is filled and hardened in the atmosphere. CONSTITUTION:A winding machine 8 is wound round so as to closely adhere to a flange 7a for stopping a leak of resin and thereon a winding 4 is wound round. After the winding 4 is wound round, further on its upper surface, a pre-preg insulator 6a is wound round so that one end part may closely adhere to the flange 7a, later drying of the winding 4 and hardening of the pre-preg insulators 5a and 6a are performed. Thereafter, a multisensory epoxy compound is filled with a filler, while resin 9, which has low viscosity, excellent heat resistance and crack resistance to be obtained by blending a silane coupling agent and a titanate coupling agent with this filler at the fixed rates respectively, is injected into a space encircled by the pre-preg insulators 5a and 6a and into a space inside the winding 4 in the atmosphere, after hardening a winding core is taken off so as to obtain a molded coil 1 thus improving heat resistance and crack resistance.

Description

[Detailed Description of the Invention] [Field of Industrial Application] The present invention relates to a resin for molding coils, etc., and a coil molded using the resin, and relates to a resin that has good crack resistance, good heat resistance, and low viscosity. The present invention also relates to a thermosetting resin composition suitable for satisfying the above requirements and a resin molded coil using the same.

[Conventional technology]

Conventionally, resins used in molds for coils, etc., have been optimized by optimizing the particle size distribution, maximum particle size, and average particle size of inorganic fillers, as proposed in Japanese Patent Application Laid-open No. 53-123457. has been mainly considered. However, this method does not take into consideration the interfacial phenomenon between the organic matrix resin and the inorganic filler, and it has been impossible to satisfy all of the requirements of reducing viscosity, improving heat resistance, and improving crack resistance.

Furthermore, JP-A-61-113642 suggests that at least one of a silane coupling agent or a titanate coupling agent is directly treated with an inorganic filler and then added to an organic matrix resin. ,
This is aimed at making the filler hydrophobic, and by improving the wettability between the filler and the resin, it is possible to obtain a resin composition that satisfies all of the following: viscosity reduction, heat resistance improvement, and crack resistance improvement. There is no disclosure of the idea behind this. 6 In addition, fillers are added to conventional resins to improve crack resistance by improving thermal conductivity and lowering the coefficient of linear expansion. Adding a filler increases the viscosity of the resin, making it difficult for the resin to enter the winding during casting. -1
As shown in No. 21207, the winding wire was not impregnated with resin.

Furthermore, in order to increase the filling amount of the resin, the particle size distribution of the filler is adjusted and a silane coupling agent is added to reduce the viscosity of the resin.
No. 009 is mentioned.

In addition, other related items include the Special Publication No. 37-15553.
No. 40-13814, etc., but these do not disclose the idea of filling the resin at atmospheric pressure.

[Problem to be solved by the invention]

The above conventional technology improves the crack resistance and heat resistance of the resin.
No consideration was given to simultaneously satisfying the following requirements: (1) Adding a large amount of filler to improve crack resistance of the resin increases the viscosity of the resin, so it is necessary to impregnate the inside of the coil with resin. In some cases, vacuum casting is required,
Large-scale casting requires vacuum casting equipment, and the voids that occur inside the coil during casting become vacuum voids, making it easier for corona to occur inside the coil.

(2) If the coil is not impregnated with resin in order to prevent corona generation, there is a problem in that the heat conduction of the coil becomes poor and the temperature of the coil increases.

In addition, in order to lower the viscosity of the resin, conventionally, a silane-based coupling agent has been used at a weight ratio of 0.5 to 2 to the filler.
% added.

In this way, when a silane-based coupling agent is added,
The viscosity is significantly reduced. However, even if the amount added is increased, the effect decreases, and the viscosity does not decrease below a certain level. For example, when 60% (Vol, %) of filler is added, the viscosity is 30-5° (p), but when 3% of coupling agent is added, the viscosity is 30-5° (p).
If more than (part by weight based on the entire resin, that is, about 0.45% based on the weight of the filler) is added, the viscosity decreases to about 20 (P). However, with this, the viscosity is still high.
, 10 (P) or less. Therefore, the filler is 6
In the case of a resin containing approximately 0% (Vol, %), it was impossible to lower the resin viscosity to 20 (P) or less using conventional techniques.

In view of the above-mentioned problems, the object of the present invention is to provide a thermosetting resin composition that has excellent heat resistance, crack resistance, and low viscosity, and that enables casting in the air using the same, thereby improving productivity and improving productivity.
The purpose of the present invention is to provide a resin molded coil with excellent heat resistance and corona characteristics.

[Means to solve the problem]

The above object is to provide a thermosetting resin composition containing a polyfunctional epoxy compound, a filler, and a coupling agent, in which a silane coupling agent and a titanate coupling agent are added to the filler as the coupling agent, respectively. This is achieved by blending them in a predetermined ratio.

Another object of the present invention is to provide a resin mold comprising a winding, inner and outer insulating layers formed on the inner and outer peripheries of the winding, and end insulating layers formed on the axial end surfaces of the winding. In the coil, the inner and outer peripheral insulating layers.

This is achieved by forming at least one of the end insulating layer and the inside of the winding from the resin composition.

[Effect]

The silane coupling agent and the titanate coupling agent blended into the thermosetting resin composition each have a synergistic effect to significantly reduce the viscosity of the thermosetting resin composition to which a large amount of filler has been added.

A thermosetting resin composition with a low viscosity can be easily filled into a resin mold coil, and the resin can be cast in the atmosphere.

As a result, the winding portion of the resin molded coil can also be filled in the atmosphere with resin to which a large amount of filler has been added, thereby reducing the linear expansion coefficient of the resin to a value close to that of the conductor. This can improve the crack resistance of the resin.

Further, the silane coupling agent and the titanate coupling agent are mixed with the filler at predetermined ratios, respectively. This can prevent the glass transition temperature of the resin from decreasing and improve the heat resistance of the resin.

〔Example〕

Embodiments of the present invention will be described below with reference to FIGS. 1 to 43. A first embodiment of the present invention will be described with reference to FIGS. 1 to 11.

FIG. 1 is a partially sectional perspective view showing the structure of a resin molded coil 1 of this embodiment. This mold coil 1
The inner and outer circumferences are molded with prepreg insulators 5a and 6a, respectively, to form an inner circumferential insulating layer 5 and an outer circumferential insulating layer 6, and a liquid resin 9 is impregnated into the inside of the winding 4 and then heated. Made by hardening.

As shown in FIG. 5, the resin is wound on a winding machine 8 so as to be in close contact with the resin leak-proofing flange 7a, and the winding wire 4 is wound thereon. As shown in FIG. 3, the winding 4 has a conductor 4a and an interlayer insulator 4b wound alternately. After winding the winding 4, a prepreg insulator 6a is further wound on the upper surface of the winding 4 so that one end is in close contact with the flange 7a, and then the winding 4 is wound.
and curing the prepreg insulators 5a and 6a. After that, a filler is filled into the polyfunctional epoxy compound, and a silane coupling agent and a titanate coupling agent are added to the filler in predetermined proportions to obtain a low-viscosity, heat-resistant, and crack-resistant product. Excellent resin 9,
As shown in FIG. 6, it is injected into the space surrounded by the prepreg insulators 5a and 6a and the space inside the winding 4 with the flange 7a facing down, and after curing, the core 7 is removed and the A molded coil 1 having a cross section as shown in FIG. 7 is obtained and is very large. By making the cross section of the winding core 7 orthogonal to the axis into a lamp shape, it is possible to obtain a rectangular resin molded coil in this embodiment as shown in FIG. In order to improve the impregnation of the resin inside the molded coil, it is necessary to lower the viscosity to 10 (P) (the viscosity at the time of injection, the temperature is about 100° C.). One way to lower the viscosity of the resin is to reduce the amount of filler added.

a. Thermal conductivity decreases.

b. The coefficient of linear expansion increases and the crack resistance decreases.

C. The cost of resin increases. Problems such as this occur.

Furthermore, if the resin is injected under high vacuum, the impregnating properties of the resin will be improved, but vacuum voids will be formed in the resin. Therefore, as shown in FIG.

Since the corona initiation voltage in the void decreases and the corona characteristics deteriorate, it is desirable to inject the resin at atmospheric pressure and sufficiently impregnate the resin.

For this purpose, it is absolutely necessary to lower the resin viscosity.

Coupling agents are used to reduce the viscosity of the resin.

Coupling agents include silane type, titanate type, etc., and silane type is generally used.

However, as shown in FIG. 8, there is a limit to this.

Specifically, in order to lower the viscosity of the resin, a silane coupling agent has conventionally been added in an amount of 0.5 to 2% by weight relative to the filler.

In this way, when a silane-based coupling agent is added,
As shown in Figure 8, the viscosity decreases considerably. but,
As the amount added increases, the effect becomes saturated, and the viscosity does not decrease below a certain level.For example, if the filler is added to 60% (Vol.
,%), the viscosity is 30 to 50 (P) without the addition of a coupling agent, but when the coupling agent is added
% (part by weight based on the entire resin, that is, about 0.45% based on the weight of the filler), the viscosity will be 20 (P).
decreases to a certain extent. Therefore, it is desirable that the amount of silane added is about 0.3 to 1.5% based on the filler.
However, the viscosity is still high and cannot be lower than 10 (P). Therefore, in a resin containing about 60% (Vol, %) of filler, the resin viscosity should be reduced to 20 (P).
It is impossible to lower the temperature below using a silane-based coupling agent alone.

Furthermore, when the amount of the coupling agent is increased, the heat resistance of the resin decreases, and the TG (glass transition temperature), which is a measure of the heat resistance, tends to decrease. In particular, in the case of titanate-based materials, it has been confirmed that the TG is significantly reduced as shown in FIG.

For example, 0.45% (weight ratio) of silane based on the filler.
The viscosity of the resin in which 0.075, 0.15, and 0.6% of titanate based on the filler is added to the resin (weight ratio of 0.5.1 and 4%, respectively, based on the entire resin) As shown in FIG. 8, the addition of titanates has a significant effect on viscosity reduction. However, even if the amount of titanate is increased by 0.15% or more, the effect of reducing viscosity is saturated, while TO is reduced and heat resistance is significantly reduced.

Therefore, the amount of titanate added is 0,005 to the filler.
It is desirable to set the content to about 0.3%. FIG. 11 shows a summary of these results. Resin A is an example of the resin of the present invention. Resin B is a conventional resin with a viscosity of 20 (
P) is high and TG is also low at 120°C. On the other hand, resin C
This is the case where only the titanate type is added, and although the resin viscosity is as low as 9 (P), there is a drawback that the TG is also low.

Therefore, in this embodiment, a small amount of titanate is added in addition to the silane to prevent a significant decrease in TG and to significantly reduce the resin viscosity. As a result, in this embodiment, TO can be set to 135° C., and it can be used as an insulator for F product connections.

The thermosetting resin composition of this example is specifically as follows.

Diglycidyl ether obtained by the reaction of bisphenol A and bisphenol F with epichlorohydrin as the epoxy compound, crystalline silica as the filler, hexahydrophthalic anhydride as the curing agent, and 2-ethyl-4 methyl as the curing accelerator. Imidazole is used as the silane coupling agent, γ-glycidoxypyltrimethoxysilane is used as the silane coupling agent, and isopropyl triisostearoyl titanate is used as the titanate coupling agent.

In addition, in order to increase the filling amount of the filler and lower the linear expansion coefficient of the resin to approach that of the wire-wound conductor, the maximum particle size of the filler was set to 80 μm as described in JP-A No. 62-224009. As below.

In addition, particles having a distribution such that the slope n of the RR5 particle size distribution diagram is 0.9 or less are used, and the particles are filled at 60% by volume.

This reduces the linear expansion coefficient of the resin to 2゜4 x 10"
(K-''), and can approach the linear expansion coefficient of aluminum used as a conductor, 2.3×1O-5 (K-'').

According to this example, since the viscosity of the resin is low, it can be cast into the windings of a resin-molded coil at atmospheric pressure without vacuum casting, and the resin can be filled into the windings to form a coil. can significantly improve the heat dissipation characteristics of

Therefore, the molded coil becomes small, and it becomes possible to manufacture a molded transformer at low cost.

Furthermore, in this embodiment, since the resin 9 is cast under atmospheric pressure, even if a void 9a is formed in the winding as shown in FIG. Therefore, as shown in FIG. 10, the corona starting voltage is high and void 9a
Even if there is electric field concentration in a part, the generation of corona can be suppressed.

A second embodiment of the invention is shown in FIG.

This molded coil 20 has inner and outer circumferences molded with prepreg insulators 5a and 6a, respectively, to form an inner circumferential insulating layer 5 and an outer circumferential insulating layer 6, and a high viscosity putty-like resin 1 is formed on the lower part.
4, a low viscosity liquid resin 9 is impregnated and injected into the inside of the winding wire from above, and then heated and cured.

In the method of manufacturing the molded coil in this embodiment, as shown in FIG. 5, a winding core 7 is set in a winding machine 8, a prepreg insulator 5a is wound on the upper surface of the winding core 7, and a winding a4 is wound on top of the winding core 7.

Also in this embodiment, the winding 4 consists of a conductor 4a and an interlayer insulator 4.
After the six windings 4 are wound alternately, a prepreg insulator 6a is further wound on its upper surface, and one end of the prepreg insulator 6a is then filled with a high viscosity putty-like resin 14 and heated. Then, the winding 4 is dried and the prepreg insulators 5a, 6a and putty-like resin 14 are cured. After that, the winding core 7 is removed, the coil is placed with the end filled with the putty-like resin 14 facing down, and a silane-based coupling agent and a titanate-based coupling agent are applied at predetermined ratios to the filler. Resin 9 with low viscosity, excellent heat resistance, and crack resistance
(hereinafter referred to as low viscosity liquid resin 9) is injected into the winding 4 from above at atmospheric pressure and cured by heating to obtain the molded coil 20.

According to this embodiment, since the winding core 7 does not require a flange, the structure is simple and can be manufactured at low cost.Furthermore, since it can be used regardless of the radial thickness of the winding 4, it is possible to produce a large variety of products in small quantities. suitable for

A third embodiment of the present invention will be described with reference to FIG.

In this embodiment, a resin layer made of hardened low-viscosity liquid resin 9 is formed only inside the winding 4.

In this embodiment, the inner insulating layer 5. of the coil 3o. Outer insulating layer 6
are respectively cured prepregs 5a.

6a, and the end insulating layers 10 at both axial ends of the winding 4 are both formed of hardened putty-like resin 14.The 6th winding g4 is made of alternately wound conductors and interlayer paper. Then, a resin layer 9 is formed by impregnating and injecting a low-viscosity liquid resin 9 and hardening the resin layer 9 inside. The method for manufacturing the resin molded coil of this embodiment is the same as that of the second embodiment until the low viscosity liquid resin 9 is injected into the winding 4 at atmospheric pressure, but the injection amount of the low viscosity liquid resin 9 is The upper end insulating layer 10 is filled with a putty-like resin 14 up to the upper end of the winding 4, and then heated and cured to obtain a molded coil 30.

A fourth embodiment of the present invention will be described with reference to FIGS. 14 and 15.

In the resin molded coil 32 in this embodiment, a resin layer 9 made of a low-viscosity liquid resin 9 is formed inside the winding 4, an outer circumferential insulating layer 6 is formed of a prepreg 6a, and an inner circumferential insulating layer 5 is made of a prepreg 5a and a low-viscosity liquid resin 9. It is formed of a resin layer 9 made of liquid resin 9, and both ends of the end insulating layer 10 are formed of putty-like resin 14.

In this embodiment, a spacer 32a is interposed between the prepreg 5a on the inner circumferential side and the winding 4, and the prepreg 5a and the winding 4 are
A low viscosity liquid resin 9 is injected into the gap between the two to form a resin layer of the low viscosity liquid resin 9 on the inner peripheral side of the 1% volume 4. The spacer 32a is preferably made of the same material as the resin to be injected, and in this embodiment, the spacer 32a is formed by hardening the low viscosity liquid resin 9.

The method for manufacturing the molded coil 32 in this embodiment includes setting the winding core 7 (not shown) in a winding machine 8 (not shown),
One winding 4, in which the inner prepreg 5a is wound around the winding core 7 and the winding 4 is wound thereon with a spacer 32a interposed therebetween, a conductor 4a and an interlayer insulator 4b are alternately wound. The length of the spacer 32a is desirably less than or equal to the axial length of the prepreg 5a and greater than or equal to the axial length of one winding 4. FIG. 15 shows a case where the length of the spacer 32a is made equal to the length of the prepreg 5a in the axial direction.

After winding of windings II & 4, the prepreg 6a is wound around the outer periphery of the first winding 4 to separate the outer periphery and form the A layer 6.Next, one end is filled with a putty-like resin 14 and the core is heated and hardened. Temaki!
! Step 4 is dried and the prepregs 5a, 6a and putty-like resin 14 are cured. Thereafter, the winding core 7 is removed and the coil is placed with the end filled with the putty-like resin 14 facing down, and a low viscosity liquid resin 9 is applied inside the winding 4 and between the prepreg 5a formed by the spacer 32a and the winding 4. Inject at atmospheric pressure into the gap between the Next, the upper end face is covered with a putty-like resin 14, and the resin molded coil 3 is heated and hardened.
Get 2.

In this embodiment, the thickness of the insulating layer on the inner peripheral side of the resin molded coil 32 is increased, so that the insulation strength between it and the iron core inserted into the space after the first turn core 7 is removed can be increased.

A fifth embodiment of the present invention will be explained with reference to FIGS. 16 and 17.

In the resin molded coil 34 in this embodiment, a resin layer 9 made of a low-viscosity liquid resin 9 is formed inside the winding 4, an inner circumferential insulating layer 5 is formed of a prepreg 5a, and an outer circumferential insulating layer 6 is made of a prepreg 6a and a low-viscosity liquid resin. It is formed of a resin layer 9 made of liquid resin 9, and both ends of the end insulating layer 10 are formed of putty-like resin 14.

In this embodiment, a spacer 34a is interposed between the prepreg 6a on the outer circumference side and the winding wire 4, and a low-viscosity liquid resin 9 is injected into the gap between the prepreg 6a and the winding wire 4 to create a low-viscosity liquid resin on the outer circumference side of the winding wire 4a. A resin layer of viscous liquid resin 9 is formed. The spacer 34a is preferably made of the same material as the resin to be injected, and in this embodiment, the spacer 34a is formed by hardening the low viscosity liquid resin 9.

The method for manufacturing the molded coil 34 in this embodiment includes setting the winding core 7 (not shown) in a winding machine 8 (not shown),
The inner prepreg 5a is wound on the winding core 7, and the winding 4 is wound thereon. After six windings 4 are wound, in which a conductor 4a and an interlayer insulator 4b are alternately wound, a prepreg 6a is wound around the outer periphery of the winding 4 via a spacer 34a. It is desirable that the length of the spacer 34a is less than or equal to the length of the prepreg 6a in the axial direction and greater than or equal to the length of one winding 4 in the axial direction. The case where it is made equal to the length of is shown.

Next, one end is filled with a putty-like resin 14 and heated and cured together with the winding core to dry the winding 4 and harden the prepregs 5a, 6a and the putty-like resin 14.

Thereafter, the winding core 7 is removed and the coil is placed with the end filled with the putty-like resin 14 facing down, and a low viscosity liquid resin 9 is applied inside the winding 4 and between the prepreg 6a formed by the spacer 34a and the winding 4. A resin-molded coil 34 is obtained by filling the upper end face of the primary resin 14 with a putty-like resin 14, which is injected into the gap between the primary coil and the resin under atmospheric pressure, and hardening it by heating.

In this embodiment, the thickness of the insulating layer on the outer circumferential side of the resin molded coil 34 is increased, and the insulation strength on the outer circumferential side of the coil can be improved, making it possible to obtain a resin molded coil with excellent insulation properties and safety. .

A sixth embodiment of the present invention will be described with reference to FIG.

In this embodiment, a resin M9 made of a low viscosity liquid resin 9 is formed inside the winding 4, an inner circumferential insulating layer 5 is formed of a prepreg 5a and a resin layer made of a low viscosity liquid resin 9, and an outer circumferential insulating layer 6 is made of a prepreg 6a. and low viscosity liquid resin 9
The resin molded coil 3
6.

In this embodiment, by interposing spacers (not shown) between the inner prepreg 5 and the winding 4 and between the outer prepreg 6a and the winding 4, the winding 4 and the prepreg 5a , 6a to form a gap into which a low-viscosity liquid resin 9 is injected.

The method for manufacturing the resin molded coil 36 in this embodiment is a combination of the methods for manufacturing the resin molded coil in the fourth and fifth embodiments.

The method for manufacturing the molded coil 36 in this embodiment includes setting the winding core 7 (not shown) in a winding machine 8 (not shown),
1 winding 4, in which an inner prepreg 5a is wound around the winding core 7, and the winding 4 is wound thereon through a spacer (not shown);
After winding a zero winding 4 in which a conductor 4a and an interlayer insulator 4b are alternately wound, a prepreg 6a is wound around the outer periphery of the winding 4 via a spacer (not shown).

Next, one end is filled with putty-like resin 14 and heated and cured together with the winding core to dry the winding 4 and harden the prepregs 5a, 6a and putty-like resin 14.Then, the winding core 7 is removed. Place the coil with the end filled with the putty-like resin 14 facing down, and wrap the low-viscosity liquid resin 9 inside the winding 4 and around the prepregs 5a and 6a formed by the spacer! 4
Inject at atmospheric pressure into the gap between the Next, the upper end surface is covered with putty-like resin 14 and heated to harden.

A resin molded coil 36 is obtained.

According to this example, the insulation strength and mechanical strength of the inner and outer circumferences of the coil can be improved, and a resin molded coil with excellent insulation properties and reliability can be obtained.

A seventh embodiment, an eighth embodiment, and a ninth embodiment of the present invention will be explained with reference to FIGS. 19, 20, and 21, respectively.

These embodiments are the fourth embodiment, the fifth embodiment, and the sixth embodiment, respectively.
In a modification of the embodiment, the upper end insulating layer is made of putty-like resin 1.
4 was replaced with low viscosity liquid resin 9.

The methods of manufacturing the resin molded coils of these Examples are the same as those of the fourth, fifth, and sixth examples except that the step of filling the upper end surface with a putty-like resin is removed. In these embodiments, instead of the putty-like resin 14, a low-viscosity liquid resin 9 is injected into the winding 4 at atmospheric pressure, and then injected until the upper end surface of the winding 4 is covered with a predetermined thickness. , then heated and cured to form resin molded coils 38, 40, 42 respectively.
This is what you get. According to these embodiments, it is not necessary to apply putty-like resin to the upper end surface, and the number of work steps is reduced.

A tenth embodiment of the present invention will be described with reference to FIG. 22.

This example is a modification of the ninth example, in which both the upper and lower ends are made of low-viscosity liquid resin 9.1 The method for manufacturing the molded coil in this example is the manufacturing method of the sixth example and the manufacturing method of the first example. This is a combination of manufacturing methods. That is, the method for manufacturing the molded coil 44 in this embodiment is to set a winding core 7 (not shown) having a resin leak-proofing flange 7a in a winding machine 8 (not shown), and then place the winding core 7 on the winding core 7. The inner prepreg 5a is wound so that one end is in close contact with the flange 7a, and the winding 4 is wound thereon with a spacer (not shown) interposed therebetween. In the winding 4, a conductor 4a and an interlayer insulator 4b are alternately wound. After winding of winding 4, winding 4
A prepreg 6a is attached to the outer periphery of the prepreg 6a via a spacer (not shown).
wind it.

The prepreg 6a is wound so that one end is in close contact with the flange 7a. After winding the prepreg 6a, the first winding 4 is dried and the prepregs 5a and 6a are cured.Then, with the flange 7a facing down, the space surrounded by the prepregs 5a and 6a, and the space between the winding 4 and the prepregs 5a and 6a are A low viscosity liquid resin 9 is injected at atmospheric pressure into the space formed by the spacer between them and the space inside the winding 4, and after curing, the winding core 7 is removed to obtain a molded coil 44. In this embodiment, the inner peripheral insulating layer 5 is formed of a prepreg 5a and a resin layer 9,
The outer circumference aNJ6 is formed by the prepreg 6a and the resin layer 9.

According to the seventh to tenth embodiments described above.

Since a layer of low viscosity liquid resin 9 is provided on the end face of the molded coil and at least one of the inner and outer circumferences of the winding 4, a resin layer with excellent airtightness and waterproof properties is provided on the surface of the winding. This improves the weather resistance of the molded coil.

Further, in the seventh to ninth embodiments, one of the end insulating layers is made of putty-like resin 14, but similarly to the tenth embodiment, both the upper and lower ends may be made of low-viscosity liquid resin 9. According to this, weather resistance can be further increased.

An eleventh embodiment of the present invention will be described with reference to FIG.

In this embodiment, a blocking layer 16 for preventing the low-viscosity liquid resin 9 from entering is provided on the upper and lower end surfaces of the winding 4, and an air layer 18 is formed inside each winding 4.

In this embodiment, the inner circumferential insulating layer 5 and the outer circumferential insulating layer 6 are formed of prepregs 5a and 6a, respectively, and blocking layers 16 made of putty-like resin 14 are formed at both ends of the winding 4. The low viscosity liquid resin 9 is injected into the space surrounded by the blocking layer 16 and the prepregs 5a, 6a and hardened.

The method for manufacturing the molded coil 50 in this embodiment is the same as the method for manufacturing the molded coil in the second embodiment up to the winding of the prepreg 6a of the periphery B layer. After winding the prepreg 6a, both end faces of the winding 4 are filled with putty-like resin 14 to a thickness sufficient to prevent penetration of the low-viscosity liquid resin. This operation is performed at atmospheric pressure, and the pressure of the air layer 18 within one winding 4 is maintained at atmospheric pressure.

Next, the prepreg 5.6a and the putty-like resin 14 are heated and cured to form the inner and outer peripheral insulating layers 5.6 and the blocking layer 16. After that, the winding core 7 is removed and the coil is placed with one end facing upward, and the prepregs 5a, 6a and the blocking layer 16
A low viscosity liquid resin 9 is injected into the space surrounded by and cured.Next, the coil is turned upside down and a low viscosity liquid resin 9 is injected into the space surrounded by the prepregs 5a, 6a at the other end and the blocking layer 16. The resin 9 is injected and hardened. As a result, a molded coil 50 can be obtained.

Since the molded coil 50 of this embodiment has an air layer inside the winding 4, one weight can be measured.

The twelfth to fourteenth embodiments of the present invention are respectively referred to as the 24th embodiment.
This will be explained with reference to FIGS. In these embodiments, an air layer 18 is used instead of the resin layer 9 inside the winding 4 of the molded coil of the fourth to sixth embodiments.

In these examples, since there is an air layer inside the winding,
Molded coils can be quantified. Furthermore, since a layer of low-viscosity liquid resin is provided on the inner and outer peripheries, the insulation strength of the inner and outer peripheries can be improved. In these embodiments, the blocking M1 provided on the inner and outer peripheries or the outer periphery of the winding 4
7 is a 6-winding wire 4 composed of an interlayer insulator 4b of the winding wire 4;
Since the upper and lower end surfaces of the molded coil are filled with the putty-like resin 14, there is no need to form a blocking layer on these surfaces.

Except for not injecting low viscosity liquid resin into volume g4,
They are the same as the fourth to sixth embodiments, respectively.

The 15th to 17th embodiments of the present invention are shown in Figures 27 to 2.
This will be explained with reference to FIG.

These embodiments are the twelfth embodiment to the fourteenth embodiment, respectively, in which the end insulating layer on the upper end surface is also formed of a low-viscosity liquid resin 9.

In these embodiments, a blocking layer 16 made of putty-like resin 14 is provided on the upper end surface of one winding 4 to prevent low-viscosity liquid resin 9 from penetrating into the winding 4 .

One turn of interlayer insulator 4 on the inner or outer circumference of the winding 4
b functions as the blocking layer 17. The manufacturing methods of the molded coils 58, 60, and 62 obtained by these examples are the manufacturing methods of the fourth to sixth examples, respectively, and the lower end insulating layer 10 is filled with putty-like resin 14 and heated. The steps up to the curing step are the same. 15th example - 1st
In all of the 7 embodiments, after this, the putty-like resin 14 is filled at the upper end of the volume 4 to a thickness sufficient to prevent the low-viscosity liquid resin 9 from penetrating, forming a blocking layer 16.
Next, low viscosity liquid resin 9 is injected into the space formed by the spacer between the volume wA4 and the inner prepreg 5a or the outer prepreg 6a, and then the prepreg 5a above the blocking layer 16 is injected.

Low viscosity liquid resin 9 is also injected into the space surrounded by 6a. The low viscosity liquid resin 9 is a prepreg 5a.

Since the interlayer insulating material 4b wound on the inner and outer circumferential surfaces of the zero winding 4, which is injected until it reaches the peripheral edge 6a, functions as a blocking layer 17, the low viscosity liquid resin 9 does not penetrate into the winding 4. This work is carried out at atmospheric pressure, and the inside of the winding 4 has an air layer with a pressure equal to the atmospheric pressure. Next, the low viscosity liquid resin 9 is heated and hardened, and the upper end surface of the winding 4 and the inside of the winding 4 are A resin layer of low viscosity liquid resin 9 is formed on the periphery or outer periphery to obtain molded coils 58, 60, and 62, respectively. According to these examples, it is possible to improve weather resistance and heat dissipation.

An 18th embodiment of the present invention will be described with reference to FIG.

This embodiment is a modification of the 17th embodiment. A blocking layer 16 is formed on both the upper and lower end surfaces of the molded coil using a putty-like resin 14, and a resin layer using a low-viscosity liquid resin 9 is formed on the upper and lower ends of the molded coil.

The manufacturing method of the molded coil 64 in this embodiment is the same as that in the sixth embodiment until the prepreg 6a is wound around the outer periphery of the winding 4 via a spacer. Both ends are filled with putty-like resin 14 to a thickness sufficient to prevent infiltration of the low-viscosity liquid resin. Next, the lower end surface of the molded coil 64 is closed, and low viscosity liquid resin 9 is injected from the upper end surface. In order to close the lower end surface, for example, a flange 7a is detachably provided on the winding core 7, and the flange 7a is brought into close contact with the lower ends of the prepregs 5a and 6a on the inner and outer peripheries before the low viscosity liquid resin 9 is injected. May be attached. The injected low-viscosity liquid resin 9 is applied to the inner periphery of the winding 4 and the prepreg 5a, and the outer periphery of the winding 4 and the prepreg 6a.
and the space formed by the flange 7a and the prepregs 5a, 6a, and the inner and outer peripheries of the winding 4 and the prepregs 5a.

6a, and then filled in the space surrounded by the blocking layer 16 at the upper end of the winding 4 and the inner and outer prepregs 5a, H6a. The low viscosity liquid resin 9 is prepreg 5a on the inner and outer peripheries,
Next, the low viscosity liquid resin 9 is heated and hardened to obtain the molded coil 64. According to this embodiment, the low viscosity liquid resin 9 is poured around the entire circumference of the first roll a4. Since a resin layer is formed, weather resistance and heat dissipation properties can be further improved.

In the above embodiments, the end face on the side where the outlet lines 2.3 are provided is set as the upper side, but the end face on the opposite side to the end face on the side where the outlet lines s2 and 3 are provided is not limited to this. may be on the upper side.

A nineteenth embodiment of the present invention will be described with reference to FIGS. 31 and 32.

This embodiment is an example in which the present invention is applied to a cast-type resin molded coil 70. In this embodiment, the winding 4 is arranged in a casting mold (not shown), and the end insulating layer 78 and the inner circumferential insulating layer 74 are arranged in a resin injection port (not shown) of the casting mold.
．． A low-viscosity liquid resin 9 is injected into the outer circumferential insulating layer 76 and the inside of the winding 4, and is heated and hardened to obtain a resin molded coil 7o having the shape shown in FIG. 32. 71 is a terminal for changing the tap. In this embodiment as well, since the resin 9 has a low viscosity, the casting operation can be carried out at atmospheric pressure, making it possible to eliminate the need for vacuum equipment and reduce equipment costs. It can be significantly reduced.

Note that FIG. 31 is a cross section taken along line AA' in FIG. 32, and in this embodiment, the resin 9 is also filled in the winding 4 as shown in the same figure.

A 20th embodiment of the present invention will be described with reference to FIG.

This embodiment is the molded coil of the 19th embodiment in which the resin 9 is not filled into the winding 4.1 The molded coil 72 according to this embodiment has an external shape as shown in FIG. 32. . In this embodiment, the upper and lower ends of the winding 4 in the axial direction are filled with a putty-like resin 14 in advance to form a blocking layer to prevent the resin 9 from penetrating into the winding 4.

A blocking layer 17 is formed on the inner and outer peripheries of the winding 4 by the wound interlayer insulator 4 . Putty-like resin 1 on the upper and lower ends of the winding 4
4 and filling the resin 9 into the casting mold (not shown)
The injection operation is performed at atmospheric pressure, and an air layer 18 at atmospheric pressure is formed inside the winding 4. In this embodiment, since the resin 9 is not injected into the space inside the winding 4, the molded coil 7
The weight of 2 can be reduced. This embodiment is suitable for a resin molded coil that has a small capacity and generates little heat.

The manufacturing method of this embodiment is the same as that of the nineteenth embodiment except that the blocking layer 16 is formed in advance on both ends of one winding 4 and then the winding 4 is placed in the casting mold.

A twenty-first embodiment of the present invention will be described with reference to FIGS. 34 to 38.

In this embodiment, the high fluidity of the low-viscosity liquid resin 9 is utilized to form ribs around the terminals on the surface of the outer peripheral insulating layer to obtain an insulation distance. 81 is a terminal on the winding start side, 82 is a terminal on the winding end side, and 83 is a tap switching terminal. Figures 35 to 37 show the BB' cross section, cc' cross section, and DD' cross section in Figure 34, respectively. show. terminal 8
1.82, ribs 84.85 are provided to surround them, respectively. The protrusion height of the ribs 84, 85 from the surface of the molded coil 80 is set smaller than the protrusion height of the terminals 81, 82, so that they do not become an obstacle when connecting the lead wires. This relationship is based on the tap switching terminal 83.
The same applies to the protruding height of the rib 86 and the protruding height of the rib 86 . The inner circumferential insulating layer 80a, the outer circumferential insulating layer 80b, and the end insulating layer 180c of the molded coil 8o are formed of a low-viscosity liquid resin 9. Since the low-viscosity liquid resin 9 has good fluidity, even if somewhat complicated irregularities are formed in the casting mold, it can be cast along them, making it possible to form ribs as in this embodiment 9 Inside the winding 4 is a low viscosity liquid resin 9.
The manufacturing method of the molded coil 80 of the six embodiments, which may or may not be injected, is the same as that of the nineteenth embodiment or the twentieth embodiment. FIG. 38 shows the molded coil 80 of this embodiment used in a single-phase transformer. The molded coil 80 is inserted into the iron core 87, and the terminal 81 has one
The next side power connection terminal 88 is connected to the terminal 82, and the connection bar is connected to the terminal 82.
Tap connection bars 90 are connected to the tap terminals 83, respectively. Note that 91 is a secondary terminal and is connected to obtain a single-phase three-wire secondary output.

A twenty-second embodiment of the present invention will be described with reference to FIGS. 39 and 40.

In this embodiment, heat dissipation ribs 92a are formed on the surface of the outer peripheral insulating layer 92c by utilizing the good fluidity and thermal conductivity of the low viscosity liquid resin 9. In this embodiment, the inner circumference insulating layer 92b, the outer circumferential insulating layer 92c, and the end insulating layer 92d of the molded coil 92 are each made of a low-viscosity liquid resin 9. In this embodiment, unevenness is formed in a casting mold (not shown) to form heat dissipating ribs 92a, and the injected low-viscosity liquid resin 9 flows along these unevenness and hardens to form heat dissipating ribs 92a. be done.

The manufacturing method of this embodiment is also the same as that of the 19th embodiment or the 20th embodiment.

Fig. 40 shows an example in which the molded coil 92 of this embodiment is used in a single-phase three-wire transformer.In this embodiment, the ribs 92a are provided only on the front side and the back side, Even if the molded coils are arranged side by side, interference between the ribs can be prevented. Furthermore, ventilation between the molded coils is not obstructed.

In the above examples, since a silane coupling agent and a titanate coupling agent are used together, the wettability between the resin and the filler is improved, and the resin becomes denser and the gaps between the molecules of the tree are reduced. airtightness and waterproofness are improved. Therefore, in the above embodiments, resin molded coils with excellent moisture absorption resistance can be obtained, and these resin molded coils can also be used in outdoor molded transformers and the like.

A twenty-third embodiment of the present invention will be described with reference to FIGS. 41 to 43.

This example is a molded coil used for a linear motor or the like.

In this embodiment, an inner insulating layer 107 and an outer insulating layer 108 are made of low viscosity liquid resin 9 around the winding 102 which has two turns.
Then, an end insulating layer 110 is formed, and low viscosity liquid resin 9 is injected into the first winding 102 as well.

The method for manufacturing a molded coil according to this embodiment includes an injection mold 10
A spacer 104 is placed inside the spacer 6, and a winding 102 is placed on top of the spacer 104.
is placed, and low viscosity liquid resin 9 is injected. In this embodiment, a concave groove 106a is formed at the bottom of the injection mold 106, and the low viscosity liquid resin 9 flows into this groove to form ribs 112. The ribs 112 function as heat radiation ribs and reinforcing ribs.

According to this example, a molded coil with excellent weather resistance and heat dissipation properties can be obtained.

In addition, in the above embodiments, the amount of filler can be significantly increased compared to conventional resins, so the cost of resin can be reduced, and since the filler has high thermal conductivity, mold Since the heat generated within the coil is transferred to the coil surface via the highly thermally conductive resin 9, the heat dissipation characteristics are significantly improved.

In addition, even if the current density of the coil conductor is increased and the amount of heat generated increases, the temperature rise inside the coil can be kept low due to its excellent heat dissipation characteristics, making it possible to make the molded coil approximately 20% smaller than before. can be achieved. Moreover, weight reduction is also possible by this.

Furthermore, it is possible to reduce material and equipment costs and obtain an inexpensive molded coil.

〔Effect of the invention〕

According to the present invention, it is possible to obtain a resin molded coil in which the resin layer has excellent heat resistance and crack resistance, the current density of the winding wire can be increased, and the coil can be made smaller and lighter.

Further, according to the present invention, a thermosetting resin composition having excellent heat resistance and crack resistance and low viscosity can be obtained.

Furthermore, according to the present invention, since the viscosity of the resin can be significantly reduced, the resin casting operation can be performed at atmospheric pressure, making the operation easier and requiring no large-scale vacuum casting equipment. It is possible to obtain a method for manufacturing a resin molded coil that can be made unnecessary and that can significantly reduce the amount of equipment.

[Brief explanation of the drawing]

FIGS. 1 and 2 are a partial cross-sectional view and bottom perspective view showing the structure of a molded coil according to the first embodiment of the present invention, and a perspective view showing the external appearance, and FIG. 4 is an enlarged view showing a part of FIG. 3, and FIGS. 5 to 7 each show a method for manufacturing a molded coil in the first embodiment of the present invention. , Figure 5 is a side view showing the state in which the inner and outer peripheral insulation and the winding wire are wound around the winding core set in the winding machine, and Figure 6 is a side view showing the state in which the winding core is removed from the winding machine and filled with resin. Fig. 7 is a side view showing the state in which curing is completed and the core is removed;
FIG. 8 is a diagram showing the change in viscosity depending on the amount of the coupling agent blended in this example, FIG. 9 is a diagram showing the change in glass transition temperature depending on the amount of the titanate coupling agent blended,
Fig. 10 is a diagram showing the relationship between the degree of vacuum and the corona starting voltage, Fig. 11 is a diagram comparing the characteristics of the resin of this embodiment and a conventional resin, and Fig. 12 is a diagram showing the molded coil in the second embodiment of the present invention. FIG. 13 is a side view with a part of the molded coil in cross section according to the third embodiment of the present invention, and FIG. 14 and FIG. A partially sectional side view and a partially sectional perspective view of the molded coil in the example, FIGS. 16 and 1
7 is a partially sectional side view and partially sectional perspective view of a molded coil according to a fifth embodiment of the present invention, and FIGS. 18 to 22 are a partially sectional side view and a partially sectional perspective view of a molded coil according to a fifth embodiment of the present invention
A side view showing a part of the molded coil in a cross section in Examples to a Tenth Example, and FIGS. 31 and 32 are respectively a sectional view and a perspective view of a molded coil according to a nineteenth embodiment of the present invention, and FIG. 33 is a cross-sectional view of a molded coil according to a twentieth embodiment of the present invention, and FIG. 38 are a perspective view showing the external shape of the molded coil in the 21st embodiment of the present invention, a sectional view showing the BB' cross section,
A sectional view showing the cC′ cross section, a sectional view showing the DD′ cross section, a perspective view showing the state in which it is used as a transformer, FIGS. 39 and 40
The figures are a perspective view showing the outer shape of a molded coil according to a twenty-second embodiment of the present invention, and a perspective view showing a state in which it is used as a transformer, and FIGS. 41 to 43 are a perspective view showing a molded coil according to a twenty-third embodiment of the present invention. They are a perspective view showing the external shape of a molded coil, a perspective view showing a state in which it is assembled into an injection mold, and a sectional view showing a state in which low viscosity liquid resin has been injected. 1.20.30.32.34.36.38.40.42
．． 4150.52.54.56.58.60.62.6
4.7o, 72.80.92, 100: Resin molded coil, 4: Winding wire, 5.74.107: Inner peripheral insulating layer, 6.
76.108: Peripheral insulating layer, 9: Resin layer, 10.78.
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Claims (18)

[Claims] 1. A resin molded coil comprising a winding, an inner insulating layer and an outer insulating layer formed on the inner and outer peripheries of the winding, respectively, and an end insulating layer formed on an axial end surface of the winding. The inner peripheral insulating layer, the outer peripheral insulating layer,
At least one of the end insulating layer and the space inside the winding is made of at least a polyfunctional epoxy compound,
A thermosetting resin composition consisting of a filler, a silane coupling agent, and a titanate coupling agent each blended in a predetermined ratio with respect to the filler was filled and cured at atmospheric pressure to form a resin layer. A resin molded coil characterized by: 2. A resin molded coil comprising a winding, an inner insulating layer and an outer insulating layer formed on the inner and outer peripheries of the winding, respectively, and an end insulating layer formed on an axial end surface of the winding. The inner peripheral insulating layer, the outer peripheral insulating layer,
At least one of the end insulating layers is thermally cured by at least a polyfunctional epoxy compound, a filler, and a silane coupling agent and a titanate coupling agent each blended in a predetermined ratio with respect to the filler. The resin layer is filled with a synthetic resin composition at atmospheric pressure and cured, and a blocking layer is provided on a surface of the winding facing the resin layer to prevent the resin from penetrating into the winding. A resin molded coil characterized by: 3. The resin molded coil according to claim 1, wherein the resin layer is formed inside the winding. 4. The resin molded coil according to claim 3, wherein the inner circumferential insulating layer and the outer circumferential insulating layer are formed of heat-cured prepreg, and the resin layer is formed on at least one of the end insulating layers. . 5. 4. The end insulating layer is characterized in that one side is the resin layer and the other side is formed of putty-like resin.
The resin molded coil described. 6. 4. The resin-molded coil according to claim 3, wherein the inner circumferential insulating layer and the outer circumferential insulating layer are formed of heat-cured prepreg, and the end insulating layer is both formed of putty-like resin. 7. Claim: wherein at least one of the inner circumferential insulating layer and the outer circumferential insulating layer is formed of heat-cured prepreg and the resin layer formed between the prepreg and the winding wire. 3. The resin molded coil described in 3. 8. 3. The resin-molded coil according to claim 2, wherein the winding includes the blocking layer on at least a surface facing the end insulating layer, and the inside thereof is maintained at atmospheric pressure. 9. Claim: wherein at least one of the inner circumferential insulating layer and the outer circumferential insulating layer is formed of heat-cured prepreg and the resin layer formed between the prepreg and the winding wire. 8. The resin molded coil according to 8. 10. 4. The resin molded coil according to claim 3, wherein the inner circumferential insulating layer, the outer circumferential insulating layer, and the end insulating layer are all formed of the resin layer. 11. 9. The resin molded coil according to claim 8, wherein the inner circumferential insulating layer, the outer circumferential insulating layer, and the end insulating layer are all formed of the resin layer. 12. The winding has a lead wire only on one end face in the axial direction, and the end insulating layer provided on the end face opposite to the lead wire has a rib on its outer surface. The resin molded coil according to claim 10. 13. a winding; an inner insulating layer and an outer insulating layer formed on the inner and outer peripheries of the winding; an end insulating layer formed on an axial end surface of the winding; and at least the inner insulating layer. , a resin layer formed by filling the outer peripheral insulating layer and the end insulating layer with a low-viscosity thermosetting resin composition at atmospheric pressure and curing by heating, the outer insulating layer having the winding on the surface thereof; 1. A resin molded coil comprising a terminal connected to a wire and a rib formed near the terminal. 14. a winding; an inner insulating layer and an outer insulating layer formed on the inner and outer peripheries of the winding; an end insulating layer formed on an axial end surface of the winding; and at least the inner insulating layer. , a resin layer formed by filling the outer peripheral insulating layer and the end insulating layer with a low-viscosity thermosetting resin composition at atmospheric pressure and curing by heating, wherein a resin layer protrudes from the surface of the outer peripheral insulating layer. A resin molded coil characterized by having ribs arranged to 15. After winding an inner insulator around the winding core, winding a wire on the inner insulator, and winding an outer insulator on the winding, one end face in the axial direction is closed to remove the inner insulator. and the outer insulator are cured, and a filler is applied to the polyfunctional epoxy compound from the opposite end face with the closed end face facing down, and a silane coupling agent and a titanate base are applied to the filler. A method for manufacturing a resin molded coil, characterized in that a low viscosity thermosetting resin composition obtained by blending a coupling agent and a coupling agent in predetermined proportions is filled at atmospheric pressure and cured by heating. 16. After winding an inner insulating material around the winding core, winding a wire on the inner insulating material, and winding an outer insulating material on the winding, one end surface in the axial direction is closed with a putty-like resin. After forming a blocking layer on the other end surface of the winding and curing the inner peripheral insulator, the outer peripheral insulator, the putty-like resin, and the blocking layer, the putty-like resin layer is placed on the lower side. A low-viscosity thermosetting resin composition containing a filler and a silane coupling agent and a titanate coupling agent in predetermined ratios to the filler is added to the polyfunctional epoxy compound from the opposite end surface. A method for manufacturing a resin molded coil, characterized by filling the coil and heating and hardening it at atmospheric pressure. 17. After the winding wire is set in a mold so as to be spaced a predetermined distance from the inner periphery of the mold, a filler made of a polyfunctional epoxy compound and a silane cup are placed in the mold at atmospheric pressure. A low-viscosity thermosetting resin composition containing a ring agent and a titanate coupling agent in predetermined ratios is filled and cured by heating to form the inside of the winding, the inner periphery of the winding, the outer periphery of the winding, and A method for manufacturing a resin molded coil, comprising forming a resin layer at the end of the winding. 18. A blocking layer for preventing liquid resin from entering is formed on the inner and outer peripheries and both end surfaces of the winding, and then the winding is set in a mold so as to be spaced a predetermined distance from the inner periphery of the mold. with filler in polyfunctional epoxy compound at atmospheric pressure within
The filler is filled with a low-viscosity thermosetting resin composition containing a silane coupling agent and a titanate coupling agent in predetermined ratios, and the inner periphery of the winding, the outer periphery of the winding, and A method for manufacturing a resin molded coil, comprising forming a resin layer at the end of the winding.