JPH05111234A - Core coil assembly for linear motor and manufacture thereof - Google Patents

Abstract

PURPOSE:To mold an epoxy layer of a uniform thickness on a gap surface by laying glass fiber on an inner bottom of a mold, engaging a semi-fabricated core coil assembly, within the mold, then pouring resin in the mold, and molding to form a core coil assembly formed with an FRP layer. CONSTITUTION:A layer of glass fiber 7a of a constant thickness is previously provided in an inner bottom of a mold. Then, a semi-fabricated core coil assembly is engaged with a gap surface 7 of teeth of a core 2 disposed down. Epoxy resin is poured in the horizontally disposed mold. After the resin is solidified, a core coil assembly 3b is removed from the mold. As a result, an FRP layer 8 is formed on the surface 7 of the teeth of the core 2 of the obtained assembly 3b. The layer 8 is formed of the layer of the fiber 7a and a resin layer 7b in such a manner that its thickness is uniformly about 0.5mm.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates generally to linear motors, and more particularly to a linear motor core coil assembly and a method of manufacturing the same.

[0002]

2. Description of the Prior Art A plan view of a core coil assembly of a linear motor as a semi-finished product before molding is shown in FIG.
2A is a view as seen from arrows B and C in FIG.
As shown in FIGS. 2B and 2C, the semi-finished product 1c of the core coil assembly is mounted on the core 2 and a core 2 configured by laminating a plurality of magnetic plates and including a plurality of teeth 2a. Coil 3
And a lead wire 4 of the coil 3 and two rows of rod-shaped legs 5 that fasten the bottom portion of the core 2 from both sides in the longitudinal direction.

The conventional molding method used to electrically insulate the coil 3 of the semi-finished product 1c of this core coil assembly and to fix it in that position is the semi-finished product of the core coil assembly shown in FIG. 2 (B). The core coil assembly 1 is attached to the gap surface of the tooth 2a in a box-shaped casting mold 6 (see FIG. 3) having an inner contour that surrounds the bottom of the product 1c and the upper surface excluding the feet 5 and the four sides on the left, right, front and back. 7 is fitted downward, epoxy resin is poured into a horizontally positioned mold 6 to solidify the resin, and then the core coil assembly is removed to obtain a core coil assembly 3a shown in FIG.

[0004]

In the above method, resin cracking may occur particularly on the gap surface 7 of the tooth 2a due to hardening shrinkage of the resin during the manufacturing process or during use as a product on the user side. There are many problems, and it is difficult to form an epoxy layer having a uniform thickness (usually 0.5 mm) on the gap surface, and it takes a lot of labor and time to correct it.

[0005]

In the present invention, glass fibers, such as glass wool, are laid on the inner bottom surface of the mold 6 in advance, and then the coil is attached to the core, and the bottom is attached from both sides on the longitudinal axis side. Tighten with two rows of legs to make a semi-finished core coil assembly. With the gap surface 7 at the bottom, the bottom and two rows of legs 5 at the top, fit into a mold and then inject resin to mold it. The above problem is solved by using a core coil assembly in which a glass fiber reinforced FRP layer (glass fiber reinforced plastic layer) is formed on the gap surface 7 of the tooth 2a.

[0006]

The FRP layer formed in the gap layer of the core by the glass fiber laid in advance and the injected resin is extremely tough and does not crack even when the resin hardens or shrinks. Since the thickness is almost constant, the formed FRP layer also has a uniform thickness.

[0007]

DESCRIPTION OF THE PREFERRED EMBODIMENTS A coil type method for a linear motor according to the present invention is different from the conventional method in that it is a mold type 6
(A) of FIG. 1 over the entire inner bottom surface (see FIG. 3).
As shown in (B) and (B), only a layer of glass fiber 7a (usually 0.18 mm) having a constant thickness is provided in advance, and the others are the same as the conventional ones, so the description thereof will be omitted to avoid duplication. As shown in FIG. 1A, which is a perspective view of the obtained core coil assembly 3b, an FRP layer 8 is formed on the gap surface 7 of the tooth 2a, and the FRP layer 8 is a partially enlarged view of FIG. As shown in B), it is composed of a layer of glass fibers 7a and a resin layer 7b and has a thickness of about 0.5.
It is uniform in mm.

[0008]

According to the present invention, the defective product rate due to the cracking of the resin during the manufacturing process was 20 to 30%. However, according to the present invention, the core model having the FRP layer on the gap surface is used.
The defective body has no defective product rate, and at the same time has no cracks from the user side, which significantly contributes to the improvement of quality and the thickness of the fiber reinforced resin layer retained on the gap surface (usually 0). 0.5 mm) can be secured stably and easily. Moreover, since the conventional mold is used, there is no need to use a separate jig and tool, and a good product can be obtained at a relatively low cost.

[Brief description of drawings]

FIG. 1A is a perspective view of a core coil assembly having a core mold body obtained by the coil mold method for a linear motor of the present invention. (B) is a partial enlarged cross-sectional view of the B portion of (A).

FIG. 2A is a plan view of the core coil assembly before the coil molding process of the linear motor. Figure 2 (B) is
It is a B arrow line view of (A). (C) is a view on arrow C of FIG. 2 (A).

FIG. 3 is a perspective view of the core coil assembly in an inverted position and fitted in a mold.

FIG. 4 is a core mode obtained by a conventional molding method.
It is a perspective view of a core coil assembly which has a field body.

[Explanation of symbols]

 1c Semi-finished product of core coil assembly 2 Core 2a Core teeth 3 Coil 3b Core coil assembly 5 Feet 6 Mold 7 Gap surface 7a Glass fiber layer 7b Epoxy resin layer 8 Fiber reinforced resin (FRP) layer

Claims (2)

[Claims] 1. A core in which a large number of magnetic plates are laminated and has a plurality of teeth to form a gap surface, a coil wound around the core and including a lead wire, and a bottom portion of the core. A linear motor composed of two rows of rod-shaped legs tightened from both side surfaces in the longitudinal direction, and an insulating resin portion which fills the remainder of the core except the bottom portion and the rod-shaped legs to insulate the coil. In the core coil assembly, the insulating resin portion is a fiber reinforced insulating resin portion including a glass fiber layer arranged in close contact with the gap surface, and an insulating resin portion surrounding the upper surface and the entire circumferential surface of the coil. A core coil assembly for a linear motor, which is characterized by being formed. 2. A method of manufacturing a core coil assembly for a linear motor according to claim 1, wherein a plurality of magnetic plates are laminated to form a core having a plurality of teeth and forming a gap surface. When the core coil assembly semi-finished product in which the coil is mounted on the core is tightened from both sides in the longitudinal direction with the bottom of the core and two rows of bar-shaped legs, and the core coil assembly semi-finished product is inserted with the gap surface facing down, Prepare a casting mold with dimensions such that the bottom of the core and the rod-shaped feet project from the upper surface, spread glass fiber on the bottom of the casting mold, and insert the core coil into the casting mold. The semi-finished product of the assembly is placed with the bottom and rod-shaped feet facing upwards, and the insulating resin is poured into this casting mold, cured and then taken out so that the fiber-reinforced insulating resin part is formed on the gap surface. Linear motor core coil assembly characterized in that Body manufacturing method.