JPH05234748A - Molded coil - Google Patents

Abstract

PURPOSE:To prevent a deviation of a flat conductor due to movement of a coil or to a pressure at the time of molding. CONSTITUTION:Four elementary coils 2 each wound with a flat conductor and provided with an insulating layer fixed by heat fusible insulating sheet between the flat conductors are fixed, and terminals 3 are so welded as to form a predetermined electric circuit. The periphery of each fixed coil 2 is covered with foamable material to provide a buffer layer. A molded insulating layer 7 molded with SMC is provided on the surface of the coil 2 provided with the buffer layer.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to, for example, a magnetic levitation railway, a so-called linear motor car. It is about coils.

[0002]

2. Description of the Related Art For example, a sidewall levitation guide coil of a magnetic levitation railway is used for levitation of a vehicle body when a linear motor is traveling at high speed. This side wall levitation guide coil must have good mechanical and electrical characteristics because voltage and magnetostriction are generated at the moment when the linear motor power passes, and the coil has uneven thickness (when the coil and the outer surface are Non-uniform in thickness). If there is uneven thickness, the electrical insulation will be reduced, and cracks will occur due to shocking magnetostriction.

By the way, the side wall levitation guide coil is manufactured as follows. First, an elemental coil is manufactured by winding a conductive rectangular conductor in a square shape. The four element coils are butted and the terminals other than the external connection terminals are welded so as to form a predetermined electric circuit. Wrap glass tape over it and fix. As shown in FIG. 7, the rectangular conductors 5 and 5 in the element coil are electrically insulated by the insulating sheet 13. Next, a sheet molding compound (hereinafter, referred to as
It is covered with a molding material such as SMC) and heat-molded.

[0004]

By the way, the side wall levitation guide coil manufactured as described above should be free from defects such as uneven thickness as described above. However,
There is a risk of uneven thickness due to the displacement of the rectangular conductor that sandwiches the insulating sheet during the heat molding, or the displacement of the element coil.

Therefore, when molding with a molding material such as SMC, the element coil fixed to the mold and the molding material such as SMC are arranged, and when molding is performed by applying temperature and pressure,
It is necessary to prevent the element coil fixed by the pressure during molding from shifting from the desired position. The displacement of the fixed element coil is caused by the uneven pressure applied to each layer of the fixed element coil due to the flow of the molding material during molding. Further, in the case of a bare coil that is formed by only insulating the flat conductors with a glass tape after insulating the flat conductors from each other, the coil layers may be displaced due to shock or vibration.

It is an object of the present invention to provide a molded coil which prevents the displacement of the rectangular conductor due to the movement of the coil and the displacement of the rectangular conductor due to the pressure during molding.

[0007]

SUMMARY OF THE INVENTION The present invention is a molded coil formed by molding an insulating material around a coil formed by winding a conductive rectangular conductor, and fixing a heat-fusible insulating sheet between the rectangular conductors. And a buffer layer formed by coating a foam material around the coil, and a second insulating layer formed by molding SMC on the outside of the buffer layer.

[0008]

With the above structure, the rectangular conductor group is fixed by the first insulating layer made of the heat-fusible insulating sheet.
Less likely to be displaced by external force such as shock and vibration during movement. Further, during molding, after the pressure is once received by the cushioning layer made of foam material, the pressure is transmitted to each coil layer through the foam material, so that the foam material acts as a cushioning material, so that the coil layers are not displaced. It can be molded without a uniform thickness. Further, since the entire coil is once wrapped with the cushioning layer made of the foam material, the molding work is easier than the case where the coil without the foam material is molded by using SMC. That is, in the case of molding a coil having no foam material, S is cut into various predetermined sizes in advance in order to prevent uneven thickness.
It is necessary to work with experience and intuition such as wrapping the coil gap and the coil periphery with the MC. On the other hand, if the coil has a cushioning layer coated with a foam material around the coil, it is not necessary to wrap the gap between the coil and the periphery of the coil with SMC, and it suffices to place SMC of a certain size on both sides of the coil. , Does not require skill to work.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the drawings. 1 is a front view showing an embodiment of the present invention, FIG.
1 is a sectional view taken along the line AA-A-A in FIG. 1, and FIG.
It is a B sectional view. 1, FIG. 2 and FIG. 3, 1 is a side wall floating guide coil, 2 is a flat conductor 5 wound, and the flat conductors are fixed by a heat-sealable insulating sheet material to form an insulating layer (not shown). The four element coils are fixed to each other as in the conventional case and are connected so as to form a predetermined electric circuit. 3 is an external connection terminal connected to the base coil 2, 4 is a mounting hole for fixing the side wall floating guide coil to a structure (not shown), 6 is a buffer layer in which the surface of the base coil 2 is covered with a foam material, Reference numeral 7 denotes a mold insulating layer obtained by molding the surface of the element coil 2 coated with the foam material with SMC.

Next, a method of manufacturing the side wall floating guide coil 1 will be described. First, the flat coil 2 is manufactured by winding the rectangular conductor 5 into a substantially square shape. At this time, as shown in FIG. 4, the heat-fusible insulating sheet 8 impregnated with the epoxy resin having a desired thickness upon completion is wound between the rectangular conductors 5 and wound. The four element coils 2 manufactured as described above are butted as shown in FIG. 5, the gap adjusting spacer 9 is appropriately inserted, and the fixing tape 10 and the fixing cord 11 are fixed to each other, and then the external connection terminal The terminals except 3 are welded so as to form a predetermined electric circuit. Next, this fixed element coil 2 is put into a drying oven and left to stand until the heat-fusible insulating sheet 8 is cured. After curing, it is left to cool to room temperature, and the whole fixed element coil 2 is covered with a foam material 12 as shown in FIG.

Next, in the molding press die set to a predetermined temperature, the fixed coil 2 is placed so that the fixed coil 2 is positioned in the center.
Place C around it as appropriate. After that, the mold insulating layer 7 is formed by applying a predetermined pressure for a required time. As described above, it is possible to obtain the side wall levitation guide coil having the element coil 2 which is not displaced.

Although the above description has been made with respect to the side wall levitation guide coil used in the magnetic levitation railway, it can be applied to a structure in which a coil wound with a rectangular conductor other than this is molded with an insulating material.

[0013]

As described above, according to the present invention, the rectangular conductors are firmly fixed to each other by the first insulating layer formed between the wound rectangular conductors, so that the rectangular conductors can be shocked during transportation or when pressed. The rectangular conductor is not displaced by an external force, and the buffer layer coated on the coil prevents the pressure during molding from directly acting on the coil, which allows the coil to maintain a predetermined coil shape. A provided mold coil can be provided.

[Brief description of drawings]

FIG. 1 is a front view showing an embodiment of the present invention.

FIG. 2 is a sectional view taken along the line AAAA in FIG.

3 is an enlarged cross-sectional view taken along line BB of FIG.

FIG. 4 is an explanatory view showing an inserted state of the heat-fusible insulating sheet in the manufacturing method according to the embodiment of the present invention.

5A and 5B are explanatory views showing a fixed state of an element coil in a manufacturing method according to an embodiment of the present invention, where FIG. 5A is a front view, FIG. 5B is a side view, and FIG. (A) C-
The state cut to the C line is shown.

FIG. 6 is an explanatory view showing a state in which the surface of the element coil is covered with a foam material in the manufacturing method according to the embodiment of the present invention.

FIG. 7 is an explanatory diagram showing an inserted state of an insulating sheet in a conventional method for manufacturing a sidewall floating guide coil.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Sidewall levitation guide coil, 2 ... Element coil, 3 ... External connection terminal, 4 ... Mounting hole, 5 ... Rectangular conductor, 6 ... Buffer layer, 7 ... Mold insulating layer, 8 ... Heat-welding insulating sheet, 12 ... Foam material.

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁵ Identification code Office reference number FI Technical display location H01F 41/12 E 8019-5E H02K 41/02 A 7346-5H

Claims (1)

[Claims] 1. A molded coil formed by molding an insulating material around a coil wound with a conductive rectangular conductor, wherein a heat-fusible sheet material is fixed between the rectangular conductors. A molded coil comprising a layer, a buffer layer formed by coating a foam material around the coil, and a second insulating layer formed by molding a sheet molding compound outside the buffer layer.