JPH06302454A - Manufacture of coil - Google Patents

Abstract

PURPOSE:To provide a coil manufacturing method wherein a low-cost wire material which is used generally can be used and a coil which can be wound easily, whose productivity is good and whose cost is low can be obtained. CONSTITUTION:In a coil manufacturing method, a wire material 2 is lap-wound in many layers on the outer circumference of a spool 1. An insulated and covered electric wire which has not been covered with an adhesive is used as the wire material 2, an adhesive 3 which contains a thermosetting resin component and an elastomer component is applied to the outer circumference of the wire material 2, the wire material 2 to which the adhesive 3 has been applied is wound on the outer circumference of the spool 1 while the wire material is being heated, and parts between wires for a coil are fixed and bonded. After the wire material 2 has been wound on the spool 1, it is heated, the parts between the wires for the coil are fixed and bonded. The wire material 2 is passed through the adhesive 3, and the adhesive 3 is applied to the outer circumference of the wire material 2. The adhesive 3 is applied to the outer circumference of the wire material 2 by a spraying operation or a coating operation.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION The coil manufacturing method of the present invention is suitable for use in manufacturing an air core coil, particularly a field coil of an electromagnetic clutch for a car air conditioner.

[0002]

2. Description of the Related Art There are various types of field coils for air conditioners. The main ones thereof are an aligned winding coil A as shown in FIG. 3 and a stepped coil B as shown in FIG.

In order to form the aligned winding coil of FIG. 3, the wire E drawn from the bobbin is passed through a pulley (not shown) to correct its bending and bending habit, and further, the wire is slid on a felt, for example. The wire rod is reciprocated between the side plates D1 and D2 arranged on both sides of the winding frame C as shown in FIG. And wrap a predetermined number of layers. In this case, for example, in FIG.
, The wire E wound from the side plate D1 side is the side plate D
When it is turned around in the vicinity of 2 and wound on the side plate D1 side, it is wound in a bale stacking method which is located in the middle of the two adjacent wire rods E wound previously.

The stepped coil shown in FIG. 4 is basically wound in the same manner as the coil shown in FIG. 3 except for the method of forming the stepped portion F. That is, when the number of winding layers is counted by the counter and reaches a predetermined number of winding layers, the rotation of the winding frame C is stopped and fixed by the electromagnetic brake, and then the brake is released. Step winding is performed. For example, in FIG. 4, when the wire E is wound from one side plate D1 direction to the side plate D2 direction, the wire rod E is not wound to the side plate D2 but is rewound in the side plate D1 direction on the way. By repeating this, as the number of winding layers increases, the number of turns is reduced by one or several turns to form the tapered step portion F. After the step F is formed, the rotation of the winding frame C is stopped, the winding end of the wire E is stopped with an adhesive tape, and the winding end is moved to a predetermined position of the coil for a predetermined length. Disconnect. Then, as shown in FIG. 4, a lead wire G is attached to the step F so that it can be accommodated within the outermost diameter of the coil, and both ends of the wire are connected together in order to connect the lead wire G to the winding E. Close.

In FIG. 4, since the wire E wound around the winding frame C is broken (disjointed) when it is removed from the winding frame C, the following disparity preventing method is usually adopted. ． After temporarily winding the end of winding of the coil wound with the resin-coated conductive wire with adhesive tape, as shown in FIG. 7 (a), coil A is wound with adhesive tape K at a plurality of circumferential positions. To prevent the resin-coated conductive wires from coming apart. Further, as shown in FIG. 7B, a method of winding a cloth tape L around the entire circumference of the coil A from the outside to prevent the coil from being deformed. ． As shown in FIG. 8, the coil A, which has been wound with the resin-coated conductive wire, is bound with the thread N, and then impregnated with insulating varnish or the like (generally vacuum impregnated), and then dried by heating to fix the resin-coated conductive wire. How to make. ． For example, as the wire E in FIG. 3, a method of using a self-bonding wire to which an adhesive is applied in advance and winding the self-bonding wire around a winding frame to manufacture a coil.

These coil fixing methods have the following problems: quality, productivity,
It is used properly depending on the price. In recent years, coils have been required to maintain the required quality, be made light, thin, short, small, and inexpensive. For example, in the case of a field coil for an electromagnetic clutch for a car air conditioner, the bobbinless coil is mainly used. . After the coil manufactured by the above-described manufacturing method is finished, it is housed in a filled core O as shown in FIG. 9 and then fixed with a casting frame resin P.

[0007]

Among the above-mentioned coil manufacturing methods, a coil manufacturing method using a resin-coated conductive wire in which an adhesive is not applied to the outer periphery of a wire is obtained because the wire itself is inexpensive. Although the cost of the coil is low, there is a problem that productivity is poor because a coil fixing means such as an adhesive tape or a thread is used after the winding process to prevent the coil from being dislocated.

Among the above-mentioned coil manufacturing methods, the coil manufacturing method using a resin-coated conductive wire in which an adhesive is applied to the outer periphery of the wire material is such that the adhesive layers of the wire material itself are adhered to form the wire layers. Since the lines are fixed,
As shown in (a), it is not necessary to stop the tape K at a plurality of points to prevent the variation, and the winding process can be automated, which has the advantage of improving productivity, but the wire itself is expensive. Therefore, there is a drawback that the price of the obtained coil becomes high.

An object of the present invention is to provide a coil manufacturing method for supplying a coil which enables use of a general and inexpensive wire rod, is easy to wind, has high productivity, and is inexpensive.

[0010]

The coil manufacturing method according to claim 1 of the present invention is a coil manufacturing method in which a wire 2 is wound in multiple layers on the outer periphery of a winding frame 1 as shown in FIG. Using an insulation-coated electric wire not covered with an adhesive, an adhesive 3 having a thermosetting resin component and an elastomer component is attached to the outer periphery of the wire 2, and the wire 2 to which the adhesive 3 is attached is heated. On the other hand, the wire is wound around the outer circumference of the winding frame 1 to fix the wire between the coils.

In the coil manufacturing method according to claim 2 of the present invention, as shown in FIG. 1, in the coil manufacturing method in which the wire 2 is wound around the outer circumference of the winding frame 1 in multiple layers, the wire 2 is coated with an adhesive. After using an uninsulated electric wire, an adhesive 3 having a thermosetting resin component and an elastomer component is attached to the outer periphery of the wire 2, and the wire 2 to which the adhesive 3 is attached is wound around the winding frame 1. It is heated so that the wire between the coils is fixed.

According to a third aspect of the present invention, there is provided a coil manufacturing method according to the first or second aspect, wherein the wire 2 comprises an adhesive 3 having a thermosetting resin component and an elastomer component.
The adhesive 3 is attached to the outer periphery of the wire 2 through the inside.

According to a fourth aspect of the present invention, in the coil production method according to the first or second aspect, the adhesive 3 having a thermosetting resin component and an elastomer component is applied to the outer periphery of the wire 2. The adhesive 3 is attached by means of.

According to a fifth aspect of the present invention, in the coil production method according to the first or second aspect, the adhesive 3 having a thermosetting resin component and an elastomer component is sprayed on the outer periphery of the wire 2. The adhesive 3 is attached.

[0015]

In the coil manufacturing method of the present invention, an adhesive 3 having a thermosetting resin component and an elastomer component is used as the adhesive 3 applied to the wire 2 before winding the wire 2 around the winding frame 1 in FIG. Since it is used, the laminated and wound wire 2 is reliably adhered by the adhesive 3. Moreover, since the drying time of the adhesive 3 to be used is short, the wire 2 can be quickly wound around the outer periphery of the winding frame 1 while drying the adhesive 3 applied to the wire 2 with hot air, and various treatments after the coil winding process can be performed. Since it is not necessary, productivity is significantly improved.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The coil manufacturing method of the present invention will be described in detail with reference to FIGS. Wire rod 2 drawn from bobbin, etc.
For example, a resin-coated conductive wire (for example, a polyester resin-coated conductive wire: an insulation-coated electric wire) is passed through the guide roller 11 and is washed through the cleaning liquid 13 in the tank 12. The cleaned wire 2 is passed through the guide roller 14 and the adhesive 3 having the thermosetting resin component and the elastomer component in the tank 15.
The adhesive 3 attached to the outer circumference of the wire 2 passes through the through hole of the drawing die 17 fixed to the floating arm 16 to remove the excess adhesive, and a predetermined amount of the adhesive 3 according to the hole diameter of the drawing die 17 is removed. Is applied to the outer periphery of the wire 2 in a uniform thickness. At this time, in order to keep the centers of the through holes of the wire rod 2 and the die 17 concentric, the die 17 has a freely rotating fri-rotating structure as shown in FIG. The adhesive 3 applied to the outer circumference of the wire 2 is coiled around the outer circumference of the winding frame 1 by the rotation of the spindle 19 while being heated by the hot air blown out from the hot air drying heater nozzle 18.
The layers of the wire 2 and the wires are fixed to each other with an adhesive 3.

As the thermosetting resin of the adhesive 3, phenol resin, epoxy resin, unsaturated polyester or the like can be used. Curing time of thermosetting resin is 160 ℃
It is preferably adjusted to 90 seconds or less. If the curing time is 160 seconds at 90 seconds or more, the fixation will be incomplete.
The peripheral speed for winding the coated conductive wire cannot be increased. Further, if the speed is increased, the curing becomes insufficient, and the adherence and various characteristics as a coil deteriorate. From this, it is more preferably 60 seconds or less at 160 ° C.

As the elastomer of the adhesive 3, polyvinyl acetate, phenoxy resin, polyvinyl formal,
It is also possible to use polyvinyl butyral, polybutadiene, epoxidized polybutadiene, ethylene vinyl acetate copolymer and the like. These elastomers can be used alone or in combination of two or more. The average molecular weight of the elastomer is preferably 30,000 to 1,000,000. If it is 30,000 or less, the sticking property will be poor, and if it is 1 million or more, the solubility will be poor.
The viscosity of the resin becomes high and the workability deteriorates. Further, as the elastomer, a so-called reactive elastomer having reactivity with the thermosetting resin used is particularly preferable.

The ratio (weight ratio) of the elastomer to the thermosetting resin is preferably 5:95 to 80:20, more preferably 10:90 to 50:50. When the ratio of the elastomer becomes small as in the case of 5:95 or less, the sticking property decreases. On the other hand, when the ratio of the elastomer is high, such as 80:20 or more, the curability decreases.

Preferred combinations of thermosetting resins and elastomers include polyvinyl formal, polyvinyl butyral and epoxidized polybutadiene for phenolic resins. Examples of the epoxy resin include phenoxy resin, polyvinyl formal, polyvinyl butyral, and epoxidized polybutadiene. For unsaturated polyesters there is polybutadiene.

The solvent of the resin is not particularly limited, but the boiling point of the solvent of the resin is preferably 70 ° C. or less from the viewpoint of the feed rate of the coated conductive wire and the remaining solvent after drying. If it is 70 ° C. or higher, the feeding speed must be slowed down, and the residual solvent tends to remain. Specifically, acetone, methyl acetate, tetrahydrofuran, hexane,
There is methanol etc. These solvents can be used alone or in combination of two or more.

The method of attaching the adhesive having the thermosetting resin component and the elastomer component to the outer periphery of the wire 2 is not limited to the method of passing the wire 2 through the adhesive 3 as described above, and for example, Alternatively, a method of spraying the adhesive 3 on the wire 2 or a method of applying it with a brush or felt may be used.

The wire 2 coated with the adhesive is heated by means such as hot air immediately before or at the same time as it is wound on the winding frame 1,
Volatile components such as the contained solvent are volatilized, and the reaction of the fixing resin is promoted to cause fusion and curing.

The heating method is also not particularly limited, and there are a method of blowing hot air from a nozzle for drying, a method of passing through a drying furnace, a method of electrically heating after winding the wire. In the case of heating with hot air, the hot air temperature cannot be generally determined because there is a tradeoff with the winding speed. As an example, when the coated conductive wire is fed at a feed rate of 150 m / min and heated with hot air from a nozzle, the hot air temperature is preferably 100 ° C to 4000 ° C. If the temperature is 100 ° C. or lower, the solvent remains, and if it is 4000 ° C. or higher, the reaction of the coil fixing resin composition proceeds too much to lose the adhesiveness and the adhesiveness deteriorates.

[0025]

Second Embodiment In the present invention, as shown in FIG. 2, the wire 2 may be inserted into the adhesive 3 from below the tank 20. In this way, the guide roller 14 of FIG. 1 becomes unnecessary. Further, it is possible to prevent air bubbles from being entrapped when entering the wire. In this case, by embedding a die 17 having a through hole through which the wire 2 can pass without difficulty in the bottom surface of the tank 20, it is possible to bond the tank 20 downward due to its surface tension, although it depends on the viscosity of the adhesive 3. It is possible to prevent the agent 3 from leaking or dripping.

[0026]

[Experimental Example 1] 50 g of S-REC B BX-5 (polyvinyl petitral, average molecular weight 140,000, trade name of Sekisui Chemical Co., Ltd.) was added to 100 g of acetone and 100 g of methanol.
Was dissolved in a mixed solvent of. Furthermore, VP-11N # 100
(Phenol resin, curing time 35 seconds: hot plate temperature 160
° C: 100g of Hitachi Chemical Co., Ltd. product name) is added,
Well dissolved. The solution was diluted with acetone so that the nonvolatile content (105 ° C., 2 hours) was 15% to obtain a coil-fixing resin composition.

Two felts impregnated with the resin composition for coil fixing are superposed on each other, and the diameter between the felts is 0.7 m.
m PEW (polyester resin-coated conductive wire) was passed through, and the coil fixing resin composition was attached to the PEW. This sticking resin-attached PEW was wound around a stainless steel winding frame having a diameter of 10 cm to form a coil. The hot air was blown so that both the fixed resin-attached PEW and the winding frame were heated. While winding this coil, hot air was sent so as to heat both the fixed resin composition-attached PEW and the winding frame 1. At this time, the winding speed was 100 m / min and the hot air temperature was 200 ° C.

[0028]

[Experimental Example 2] 50 g of YP-50 (phenoxy resin, average molecular weight 40,000, trade name of Tohto Kasei Co., Ltd.) was dissolved in 100 g of tetrahydrofuran. Further, 50 g of Epicoat 1001 (bisphenol type epoxy resin, trade name of Yuka Shell Epoxy Co., Ltd.) was added to 100 g of acetone.
And the curing time at a hot plate temperature of 160 ° C. is 6
2-Ethyl-4-methyl-imidazole was added at 0 seconds. After adding the above YP-50 solution to this, it was diluted with tetrahydrofuran so that the nonvolatile content (150 ° C., 2 hours) was 20% to obtain a resin composition for coil fixing.

Similar to Experimental Example 1, two felts impregnated with the coil-fixing resin composition were superposed, PEW (polyester resin-coated conductive wire) having a diameter of 0.7 mm was passed between the felts, and the PEW was the same. The coil fixing resin composition was adhered to the. The PEW to which the fixing resin composition was attached was wound around a stainless steel winding frame having a diameter of about 10 cm to form a coil. While winding this coil, hot air was sent so that both the fixed resin-attached PEW and the winding frame were heated. At this time, the winding speed was 100 m / min and the hot air temperature was 200 ° C.

[0030]

[Comparative Example] VP-11 # which is a thermosetting phenolic resin
Only 100 was diluted with methanol so that the nonvolatile content was 30% to obtain a coil fixing resin composition. As in Experimental Example 1, two felts impregnated with the coil-fixing resin composition were superposed on each other, and P having a diameter of 0.7 mm was placed between the felts.
The EW was passed through and the coil-adhesive resin composition was attached to the PEW. This fixed resin-attached PEW was wound around a stainless steel winding frame with a diameter of about 10 cm to form a coil. While winding this coil, hot air was sent so that both the fixed resin-attached PEW and the winding frame were heated. Winding speed 100m /
Min, the hot air temperature was 200 ° C.

Table 1 shows the sticking properties of the coils obtained in Experimental Examples 1 and 2 and Comparative Example.

[0032]

【table 1】

[0033]

The coil manufacturing method of the present invention has the following effects. (1) Wire material 4 with adhesive 3 having low viscosity, quick drying and stability
Since the wire 2 is wound while being dried with hot air or after being dried with hot air, at the same time when the coil is wound up, the wire layers and adjacent wires are fixed with the adhesive 3 and winding work is remarkably performed. improves. (2) Even if the coil wound around the winding frame is removed from the winding frame, the shape of the coil does not collapse. (3) Since the conventional resin-coated conductive wire that can be obtained at a low cost can be used, the obtained coil is also inexpensive.

[0034]

[Brief description of drawings]

FIG. 1 is an explanatory view showing an embodiment of a coil manufacturing method of the present invention.

FIG. 2 is an explanatory view of a die portion in the coil manufacturing method of the present invention.

FIG. 3 is an explanatory view showing an example of a conventional aligned winding coil.

FIG. 4 is an explanatory diagram showing an example of a stepped coil.

5A and 5B are cross-sectional views of different examples of wire rods used in conventional coils.

FIG. 6 is an explanatory view of a conventional method for winding an aligned winding coil.

7 (a) and 7 (b) are different explanatory views of a conventional coil dislocation preventing structure.

FIG. 8 is an explanatory view of another example of the conventional coil dislocation preventing structure.

FIG. 9A is a vertical cross-sectional view showing a state in which a conventional filled coil is housed in a filled core and a resin is cast, and FIG.
FIG. 4 is a plan view of the same state.

[Explanation of symbols]

 1 reel 2 wire 3 adhesive

─────────────────────────────────────────────────── ───

[Procedure amendment]

[Submission date] June 17, 1993

[Procedure Amendment 1]

[Document name to be amended] Statement

[Name of item to be corrected] 0024

[Correction method] Change

[Correction content]

The heating method is also not particularly limited, and there are a method of blowing hot air from a nozzle for drying, a method of passing through a drying furnace, a method of electrically heating after winding the wire. In the case of heating with hot air, the hot air temperature cannot be generally determined because there is a tradeoff with the winding speed. As an example, when the coated conductive wire is fed at a speed of 150 m / min and heated with hot air coming out of the nozzle, the hot air temperature is preferably 100 ° C to 400 ° C. When the temperature is 100 ° C. or lower, the solvent remains, and when the temperature is 400 ° C. or higher, the reaction of the resin composition for coil fixing progresses too much to lose the adhesiveness and the adhesiveness deteriorates.

[Procedure Amendment 2]

[Document name to be amended] Statement

[Correction target item name] 0033

[Correction method] Change

[Correction content]

[0033]

The coil manufacturing method of the present invention has the following effects. (1) Wire material 4 with adhesive 3 having low viscosity, quick drying and stability
Since the wire 2 is wound while being dried with hot air or after being dried with hot air, at the same time when the coil is wound up, the wire layers and adjacent wires are fixed with the adhesive 3 and winding work is remarkably performed. improves. (2) Remove the coil wound on the bobbin from the bobbin is not Na collapsed shape of the coil. (3) Since the conventional resin-coated conductive wire that can be obtained at a low cost can be used, the obtained coil is also inexpensive.

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁵ Identification number Internal reference number FI Technical indication location H01F 41/12 Z (72) Inventor Kohei Yasawa 1772-1 Kagoku, Yuki-shi, Ibaraki Hitachi Chemical Co., Ltd. (72) Inventor Hideo Kawashima, 714 Kamisano-cho, Takasaki-shi, Gunma Tokuden Procell Co., Ltd.

Claims (5)

[Claims] 1. A method for manufacturing a coil in which a wire rod 2 is wound in multiple layers on the outer circumference of a winding frame 1, an insulating coated electric wire not covered with an adhesive is used as the wire rod 2, and the outer circumference of the wire rod 2 is thermosettable. An adhesive 3 having a resin component and an elastomer component is adhered, and the wire 2 to which the adhesive 3 is adhered is wound around the outer periphery of the winding frame 1 to fix the wire between the coils. Coil manufacturing method. 2. A method for manufacturing a coil in which a wire rod 2 is wound around an outer circumference of a winding frame 1 in a multi-layered manner, and an insulated coated electric wire not covered with an adhesive is used as the wire rod 2, and the outer circumference of the wire rod 2 is thermosetting. An adhesive 3 having a resin component and an elastomer component is attached, and the wire 2 to which the adhesive 3 is attached is wound around the winding frame 1 and then heated to fix the wire between the coils. Coil manufacturing method. 3. The coil manufacturing method according to claim 1, wherein the wire 2 is passed through an adhesive 3 having a thermosetting resin component and an elastomer component, and the wire 3 is attached to the outer periphery of the wire 2. A characteristic coil manufacturing method. 4. The coil manufacturing method according to claim 1, wherein the adhesive 3 having a thermosetting resin component and an elastomer component is applied to the outer periphery of the wire 2 so that the adhesive 3 is attached. A coil manufacturing method characterized by the above. 5. The method of manufacturing a coil according to claim 1, wherein the adhesive 3 having a thermosetting resin component and an elastomer component is sprayed on the outer periphery of the wire 2.
A coil manufacturing method, characterized in that the coil is attached.